Scott System
Case Study
Reusable EPS Void Forms for the Lackawanna Cutoff – Andover Station
Project
Overview
The Lackawanna Cutoff is a historic rail corridor in New Jersey, and its rehabilitation has brought new infrastructure demands along the route. At the Andover Station, a new culvert required precast concrete formwork engineered for both dimensional precision and production efficiency.
Scott System collaborated with LHV Precast to design and fabricate custom EPS foam culvert formwork for the precast concrete construction. The solution was built around a reusable form strategy that allowed the same set of forms to serve both sides of the culvert, reducing material requirements without compromising accuracy or surface quality.
The Challenges
Culvert formwork must maintain precise geometry under concrete pressure and remain efficient across repeated uses. For a two-sided culvert, the most efficient solution is a single set of forms engineered for both applications. Traditional wood formwork often fails to deliver this flexibility, as it is prone to moisture, warping, and wear. These limitations introduce production risks where repeatable geometry and surface quality are required.
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The project required a durable material capable of holding tight tolerances and producing a consistent surface through multiple pours without degradation.
Proposed Solution
Scott System engineered custom void forms from 2.0-pound-density EPS foam, CNC-milled to the culvert’s dimensional specifications and coated with polyurethane on the casting face.
- 2.0# Density EPS Foam: Provides superior compressive strength and durability compared to standard foam, ensuring geometry is maintained under concrete pressure through repeated use.
- Polyurethane Coating: Protects the CNC-milled casting face, preserving surface quality and precision across multiple pours.
- CNC Milling: Ensures high-precision culvert geometry and eliminates dimensional variability associated with hand-cutting or wood forming.
- Reusability: Engineered for use on both sides of the culvert, reducing formwork costs and streamlining logistics without sacrificing accuracy.
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Components for Success
- Performance-Grade Density: 2.0-lb EPS maintains geometry and surface integrity under repeated use better than standard foam.
- Durable Coating: Polyurethane protects the CNC-milled face, ensuring surface quality across multiple casts.
- Efficiency by Design: Forms were engineered for use on both sides of the culvert, reducing costs and streamlining logistics.
- CNC Precision: Delivers the high dimensional repeatability required for consistent precast concrete production.
Products Used
Custom EPS Foam Void Forms: 2.0# density, CNC-milled, engineered for reuse on both sides of the culvert.
Polyurethane Coating: Applied to casting face for durability and surface consistency across repeated pours.
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The Outcome
The custom EPS void forms delivered precise, repeatable geometry across the culvert’s precast concrete construction, with a reusable form strategy that reduced material requirements and kept LHV Precast’s production process efficient. The polyurethane-coated casting face maintained surface quality through every pour, and the 2.0-pound-density EPS held its geometry through the demands of a precast production environment.
For infrastructure applications where formwork must be accurate, durable, and efficient across repeated use, Scott System’s CNC-milled EPS foam void forms offer a purpose-engineered alternative to conventional forming materials, built to the geometry the project requires and the production demands the precast process places on it.