This project located in Put-In Bay, Ohio, a resort island in Lake Erie, required the construction of over 3,000 lineal feet of poured concrete seawall. Instead of building a vertical seawall the engineers developed a contoured design to repel oncoming waves back into the bay. Various parts of the seawall were different heights due to the geography along the coastline. The forms, produced in 48” wide sections out of expanded polystyrene, ranged from 5' to 10' tall. To handle the weight of the wet concrete, the density of the forms varied based upon their height, ranging from 1.15 lb per cubic ft to 2.4 lb per cubic foot. Using an attaching system patented by Universal Foam Products in 2018, the contoured forms were attached to the contractors straight forms by securing with screws into strips of OSB placed in slots in the EPS forms. The forms were ferried across the bay in 53' trailers.
