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Bridge-in-a-Backpack Concrete Bridges. Concrete Savings. Friday, February 10, 2012

Bridge-in-a-Backpack Concrete Bridges. Concrete Savings. Friday, February 10, 2012. Composite Arch “Bridge-in-a-Backpack” System. Image Credit: NY Times, University of Maine. “Corrosion- free b ridge using high-performance composites with cast-in-place concrete”.

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Bridge-in-a-Backpack Concrete Bridges. Concrete Savings. Friday, February 10, 2012

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  1. Bridge-in-a-Backpack Concrete Bridges. Concrete Savings. Friday, February 10, 2012

  2. Composite Arch “Bridge-in-a-Backpack” System Image Credit: NY Times, University of Maine • “Corrosion-free bridge using high-performance composites with cast-in-place concrete” Secretary of Transportation Ray LaHood Speaks about innovations such as Bridge-in-a-Backpack at Univ. Maine

  3. National Recognition for Bridge-in-a-Backpack AASHTO TIG 2011 Focus Technology 2011 Charles Pankow Award for Innovation 2011 Engineering Excellence Grand Award 2010 Award for Composites Excellence Most Creative Application Also recently featured in: ENR, Concrete International, Popular Science, Popular Mechanics, NY Times…

  4. Advanced Infrastructure Technologies Product AIT designs & manufactures FRP composite tubes for construction Ability to supply a complete engineered bridge system Packages: FRP arches + composite decking, modular FRP headwalls Structural Design *AIT’s engineers design the composite arch bridge superstructure Can design the bridge substructure, internally or with consultants Optimization to maximize efficiency of structure Local manufacturing and installation Carbon Fiber Bridge Superstructures Safe, Fast, Designed with Redundant Strength Characteristics Concrete Bridges Concrete Savings

  5. Summary & Opportunities Bridge-in-a-Backpack Innovative system for short- to medium-span bridge construction All Bridges designed for AASHTO LRFD Specs Fast and simple to construct Minimal transportation and equipment needs Durable – long life and minimal maintenance Enhanced material performance makes for safe, efficient, economical structure Advanced Infrastructure Technologies offers: An engineered bridge superstructure system Full superstructure design Limited substructure design Optimization to ensure efficient design • www.aitbridges.com

  6. FRP Composite tubes Carbon & Glass Fibers Marine Grade Vinylester Resin All Bridges designed for AASHTO LRFD Specs Fully Manufactured in USA, Maine Ability to manufacture locally “Bridge-in-a-Backpack” Composite Arches

  7. 4 -6 week standard lead times Can rush delivery in under 20 days when necessary Composite Arch Manufacturing Process 1. Carbon Tubes assembled and Inflated 2. Bend to required arch geometry 3. Infused with durable vinyl ester resin Manufacturing of a 15” diameter 48’ span composite arch

  8. Arch delivery/unloading Arrives ready for Install - No heavy equipment needed

  9. Functions of the FRP Arch Tube Stay-in-place form for concrete Structural reinforcement for concrete Eliminates need for rebar installation, Enhances concrete performance Confined Unconfined Three Components of FRP Reinforcement Confined concrete demonstrates significant ductility over unconfined

  10. Functions of the FRP Arch Tube Environmental protection Reduces bridge maintenance requirements Steel rusts and expands causing concrete spalling Spalling concrete exposes more reinforcement Concrete Corrosion Cycle

  11. Constructability and Concrete Filling • Arches placed in one day • Fill with Self Consolidating Concrete (SCC) • No rodding/vibration required • AIT provides standard specifications for concrete mix Pumping concrete into arches Attach decking on hollow arches

  12. McGee Bridge Replacement CONSTRUCTION SEQUENCE • Demo. existing steel bridge • Excavate for footings • Drill bedrock, form footings • Arch installation • Pour concrete footings • Install composite decking • Fill arches with concrete • Erect composite headwalls • Pour deck concrete • Backfill bridge, install geogrid • Finish grading • Guardrails and cleanup 12 Days Total Construction Time

  13. Headwalls, Wingwalls, & Backfill After arches are filled with SCC, headwalls and wingwalls are erected, and the bridge is backfilled

  14. Arch End Treatments – Headwall Options Multiple options to meet any Engineering, Cost, or Aesthetic Needs FRP Panel Walls MSE or Through-Tied Compatible with skewed bridges Lightweight, easy to install Durable, and cost competitive Concrete – Precast or CIP MSE, Through-Tied, or Gravity PC Panel, PCMG Units, Cast-in-place Versatile design options More conventional aesthetic

  15. Benefits – Save time, Save Money, Last Longer All Bridges designed for AASHTO LRFD Specs Bridge superstructure built in less than 2 weeks Joint-free, steel-free structure Composites utilized for all major components in superstructure Provides 100+ years of service with very little maintenance Replaces all Concrete, Precast Concrete and Steel Alternatives Natural stream bed maintained, bottomless, no disruption to hydraulics Craig Dilger for The New York Times

  16. Design of a Buried Composite Arch Bridge • Cast in place, buried concrete arch bridge • AASHTO LRFD, Section 12 – Buried Structures • AASHTO LRFD, Section 5 – Concrete Structures • AASHTO LRFD, Section 3 – Loads & Load Factors • Dead Loads (DC, DW), Soil Loads (EV, EH) • Live Load (HL-93)

  17. Design of Concrete-Filled FRP Tubular Arches All Bridges designed for AASHTO LRFD Specs Proposed AASHTO LRFD Guide Specifications for Design of Concrete-Filled FRP Tubes for Flexural and Axial Members Closed-form, simplified method for design of Concrete-Filled FRP Tubes (CFFT’s) Bending (φMn), Axial (φPn) , Shear (φVn) Combined Axial and Bending (interaction diagrams) Connection detailing Generic in nature – applies to all CFFT’s Presented to AASHTO’s T-6 (FRP) Committee in May 2011, currently under review

  18. Projects Completed & Underway Bradley Belfast Fitchburg Caribou

  19. Opportunities – Anywhere a concrete bridge is needed Useful for a wide range of bridge geometries/site conditions Single-radius arches with rise/span from 15%-50% Variable radius arches up to 48’ span Single and multi-span, Including highly skewed bridges

  20. Auburn, Maine Project Details Year: 2010 Span: 38'-0" Rise: 9'-6" Width: 38' Skew: 15° Arches: 12" diameter Headwall: cast-in-place concrete and precast modular gravity wall Owner: MaineDOT Engineer: Kleinfelder •SEA Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced steel beam • Widened river opening • Selected as a national 2011 Engineering Excellence Grand Award winner by the American Council of Engineering Companies (ACEC).

  21. Bradley, Maine Project Details Year: 2010 Span: 28'-6" Rise: 6'-0" Width: 34' Skew: 19° Arches: 12" diameter Headwall: FRP composite wall panels with through ties Owner: MaineDOT Engineer: Kleinfelder •SEA Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced pipe culverts • Widened opening, clear span • Out of the water • Reduced permitting needs / time • Full FRP bridge – superstructure + headwalls • Corrosion resistant means of construction and soil retention

  22. Belfast, Maine Project Details Year: 2010 Span: 47'-7" Rise: 11'-0" Width: 45' Skew: 0° Arches: 15" diameter Headwall: cast-in-place concrete and precast modular gravity wall Owner: MaineDOT Engineer: Kleinfelder •SEA Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced concrete T-beam • Widened opening • 50 yards from Belfast Reservoir dam • Constructed with 15" diameter tubes. With only 25% more carbon fiber than their 12" alternatives these arches provide twice the bending strength

  23. Fitchburg, Massachusetts Project Details Year: 2011 Span: 37'-7" Rise: 5'-7" Width: 36' Skew: 30° Arches: 12" diameter Headwall: Composite panels + MSE wall with geo grid reinforcement Owner: MassDOT Engineer: Greenman-Pedersen Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced concrete T-beam • Clear span, pier removed • Arches carried into place by 5 workers • Accelerated Bridge Program for the replacement of the Scott Reservoir Outlet bridge • Composite headwall system with MSE walls

  24. Gov. Deval Patrick Of MA & Local Officials Advancing US Technology

  25. Anson, Maine Project Details Year: 2009 Span: 27'-7" Rise: 4'-5" Width: 25' Skew: 15° Arches: 12" diameter Headwall: corrugated composite panels + MSE wall with geo grid reinforcement Owner: Town of Anson, Maine Engineer: AIT Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced steel beam • $90,000 total project cost, $5,000 better than lowest alternative bid • Municipal owner, local contractor • Superstructure placed in 8 hours • Was replaced start to finish in twelve working days

  26. Pinkham's Grant, New Hampshire Project Details Year: 2011 Span: 23'-8" Rise: 6'-0" Width: 26' Skew: 0° Arches: 12" diameter Headwall: composite sheet pile with through ties Owner: NHDOT Engineer: NHDOT / AIT Before: www.aitbridges.com Concrete Bridges. Concrete Savings. After: • Highlights • Replaced steel beam • No heavy equipment used • Near the base of Mt. Washington • Exposed to extreme conditions, flash flooding and huge snow fall levels • Was replaced start to finish less than 27 working days

  27. Ellsworth Maine -- Maine DOT Skew Bridge Example 38% footprint reduction compared to precast concrete www.aitbridges.com Option B (Chosen) – AIT Arch Bridge: Skewed Alignment Savings (~1775 sq. ft.) Concrete Bridges. Concrete Savings. Option A – Precast Concrete Arch: Square Alignment (~2870 sq.ft.)

  28. Summary and Quick Facts on CFFT Arch Bridges • Cost Effective and Fast Installation • Light weight product– reduces equipment transportation needs • Erected with a small crew, no skilled labor • Performs up to 2x lifespan of conventional materials • Accelerated Bridge Construction • Rapid design, fabrication, and delivery • Innovative Product Application • Rapid fabrication our facility or option to fabricate at/near jobsite • Hybrid composite-concrete system improves material performance • Steel free superstructure • Reduced carbon footprint • Performance Tested • Design/tested to exceed AASHTO load requirements • Superior redundancy – safe system • Corrosion resistant materials • Field load testing indicates even greater levels of safety CONCRETE BRIDGES - CONCRETE SAVINGS.

  29. www.aitbridges.com Concrete Bridges. Concrete Savings.

  30. Inspection and Maintenance • AIT provides owners with an inspection manual to augment existing inspection programs and procedures • Includes guidance for identifying damage and maintenance needs with composite materials • Covers system specific considerations when inspecting a Bridge-in-a-Backpack™ structure • Arches • Decking • Headwalls • Maintenance and repair with composites is an established science. Composite technicians have been successfully repairing composites in marine and aviation applications for decades.

  31. Composite Arch “Bridge-in-a-Backpack” System Image Credit: NY Times, University of Maine

  32. Advanced Infrastructure Technologies Product AIT designs & manufactures FRP composite tubes for construction Ability to supply a complete engineered bridge system Packages: FRP arches + composite decking, modular FRP headwalls Structural Design AIT’s engineers design the composite arch bridge superstructure Can design the bridge substructure, internally or with consultants Optimization to maximize efficiency of structure Local manufacturing and installation Carbon Fiber Bridge Superstructures Safe, Fast, Designed with Redundant Strength Characteristics Concrete Bridges Concrete Savings

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