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Composite Arch “Bridge-in-a-Backpack” System

Composite Arch “Bridge-in-a-Backpack” System. Outline What & How? Design options Overview of recent projects Specific project details Performance tested in Lab AIT’s services “ How can we work with you? ”. What is the “ Bridge-in-a-Backpack ” System.

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Composite Arch “Bridge-in-a-Backpack” System

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  1. Composite Arch “Bridge-in-a-Backpack” System Outline What & How? Design options Overview of recent projects Specific project details Performance tested in Lab AIT’s services “ How can we work with you? ”

  2. What is the “ Bridge-in-a-Backpack ” System Carbon Fiber Composite + Concrete Arch Superstructure “ A Hybrid bridge system combining benefits of high-performance composites with durability and cost savings of cast-in-place concrete” Image Credit – NY Times/University of Maine

  3. Projects Completed & Underway Bradley Belfast Fitchburg Caribou

  4. Design Options - Headwalls Multiple options to meet the Engineering, Economic, and Aesthetic requirements of the site FRP Panel Walls MSE or Through-Tied Configurations 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

  5. Headwall Options for Test-Level 4 Design Wall-mounted Barriers Precast or CIP Gravity Wall Precast Panel MSE Walls

  6. McGee Bridge Replacement Example – 28’ Span 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 Low Bid Against Steel, Concrete, Wood

  7. A note on footings Steel H-piles Spread Footings Royal River Bridge, Auburn, ME Perkins Bridge, Belfast, ME

  8. Caribou Connector Bridge • Key Metrics • Span – 54’-2” • Rise – 12’-0½” • Rise/Span – 22% • Skew – 30 deg • 22 – 15” Diameter Arches • Arch weight ~300lb each • Precast Concrete MSE Headwalls/Wingwalls

  9. Caribou Connector Bridge

  10. Caribou Connector Bridge

  11. How we got here- “Bridges to the future, now” • Maine’s Composites Initiative • Six bridges in two years • Variety of bridges to best gage how system fit’s into Maine’s bridge inventory • 28-55’ spans • Stream/road crossing • Foundation types • Headwall designs • Also being used in: • Massachusetts • New Hampshire • Michigan • Proposals in 11 states & 3 countries outside the US FHWA’s Public Interest Finding: • Allows for federal funding on projects where aspects deviate from typical requirements, when in the interest of the public. i.e. in cases of “Cost-Effectiveness or System Integrity…” [FHWA] • Simple application process – approval from FHWA in as little as 2 days [FHWA Contract Administration Core Curriculum Manual, Section 3.C, http://www.fhwa.dot.gov/construction/cqit/findings.cfm] Design-Build - Detail-Build - Value Engineering

  12. Performance Testing: Arch Testing HL-93 Design Load Equivalent

  13. National Recognition for Bridge-in-a-Backpack AASHTO TIG - 2011 Focus Technology Engineering Excellence Award Royal River Bridge, Auburn, ME (Along with Maine DOT & Kleinfelder|SEA) 2010 Award for Composites Excellence Most Creative Application Product featured in: Engineering News Record, The NY Times, Concrete International, Popular Science, Popular Mechanics, The Boston Globe American Society of Civil Engineers 2011 Charles Pankow Award for Innovation

  14. 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

  15. What can AIT do for you? Structural Design AIT’s engineers design the composite arch bridge superstructure AIT can design the bridge substructure, internally or with consultants Optimization to maximize efficiency of structure Supply AIT supplies a complete engineered bridge system Packages: arches/decking, modular FRP headwalls Installation Oversight Daniel Bannon Structural Engineer Jonathan Kenerson Manufacturing Manager

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