Carbon Fiber Reinforced Polymer (FRP) Composite Tubes Bridge-in-a-Backpack in collaboration with

Transcription

1 Carbon Fiber Reinforced Polymer (FRP) Composite Tubes Bridge-in-a-Backpack in collaboration with

2 Who is AIT Advanced Infrastructure Technologies? Product Offering 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 AIT is partnered with University of Maine to commercialize Bridge-in-a-Backpack carbon fiber composite technologies for infrastructure construction Designs & Manufactures FRP tubes, Headwalls, and complete Bridge Systems Numerous Aesthetic options to beautify Qualified Small Business Enterprise Daniel Bannon Structural Engineer Jonathan Kenerson Manufacturing Manager

3 What is Bridge-in-a-Backpack? Composite + Concrete Arch Superstructure System A hybrid bridge superstructure system combining the strength and longevity of high-performance composites with durability and cost savings of cast-in-place concrete Image Credit NY Times/University of Maine

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

5 Three Functions of the FRP Arch Tube # 1. Stay-in-place form for concrete structures Temporary Formwork for Arches Concrete Engineers Handbook, McGraw-Hill, 1918 Arches and decking are the only formwork needed to stabilize the structure Lightweight, permanent shell encases concrete Eliminates need for temporary formwork

6 Three Functions of the FRP Arch Tube # 2. Structural reinforcement for concrete Confined Unconfined Three Components of FRP Reinforcement Confined concrete demonstrates significant ductility over unconfined Eliminates need for rebar installation, Enhances concrete performance

7 Three Functions of the FRP Arch Tube # 3. Environmental protection for concrete Steel rusts and expands causing concrete spalling Spalling concrete exposes more reinforcement Concrete Corrosion Cycle Drastically reduces maintenance requirements & bridge life cycle costs

8 Buried Arch Structures Strong, Reliable & Aesthetically Pleasing Structures Design Benefits Arch efficiently carries load in compression Soil contributes to: Load distribution Passive restraint of structure Efficient soil-structure system response Much of structure made up of soil a very inexpensive material No at-grade concrete deck to deteriorate No issues with icing of deck/road surface State of Technology Current models neglect majority of soil restraint Correlation with field data confirms considerable conservatism Designed to exceed AASHTO HL-93 Loads

9 Applied Load (kip) Performance Testing: Load Deflection Testing 10 years of R&D at University of Maine Composites Labs Load-Deflection Response of Concrete-Filled FRP Tubular Arch HL-93 Design Load Equivalent Vertical Deflection at Crown (in) Initial Static Test to Failure Post-Failure Behavior

10 Applied Load (kip) Performance Testing: Arch Response / Capacity Testing Safety First, Exceeds HL-93 Design Loads, Double Redundancy, No Catastrophic Failures Experimental & Predicted Capacity Failure Load (kip) COV No. Percent Diff. Initial Secondary Experimental % 3 Predicted Experimental % 3 Predicted % 1.10% Load-Deflection Response of Concrete-Filled FRP Tubular Arch 80 Initial hinge at crown Subsequent hinges at shoulders Vertical Deflection at Crown (in) Initial Static Test to Failure Post-Failure Behavior

11 Implementation - Bridge Replacement - Maine DOT Neal Bridge, Maine DOT Demonstration Project in 2008 First installation of a composite arch system 23 Arches Installed * Design enhancements allow for wider spacing, lowering costs Bridge superstructure built in less than 2 weeks Arches Filled with Concrete Headwalls Installed, Bridge Backfilled Joint-free, steel-free structure expected to provide 100+ years of service with very little maintenance Composites utilized for all major components in superstructure Natural stream bed maintained, no disruption to hydraulics Craig Dilger for The New York Times Composite Structure Cost-Competitive with Precast Concrete and Steel Alternatives

12 McGee Bridge Replacement Low Bid vs. Steel, Concrete, Wood CONSTRUCTION SEQUENCE 1. Demo. existing steel bridge 2. Excavate for footings 3. Drill bedrock, form footings 4. Arch installation 5. Pour concrete footings 6. Install composite decking 7. Fill arches with concrete 8. Erect composite headwalls 9. Pour deck concrete 10. Backfill bridge, install geogrid 11. Finish grading 12. Guardrails and cleanup 12 Days Total Construction Time

13 Selected Structures We ve Done Owner Span (ft) Rise (ft) Width (ft) DOT Municipal # of Arches Headwall Type Foundation Type Previous Bridge Type Spread Footings, FRP Panel - Buried Concrete Medium Depth Geogrid Slab/Girder Bedrock FRP Panel - Geogrid Spread Footings, Shallow Bedrock DOT Precast T-Wall Steel H-Pile DOT Precast MSE Panel DOT Precast T-Wall DOT FRP Panel - Geogrid Private None DOT DOT FRP Panel - Through-Tied Precast MSE Panel Spread Footings, Medium Depth Bedrock Spread Footings, Shallow Bedrock Spread Footings on Compacted Gravel Spread Footings on Compacted Gravel Steel H-Pile Option of Steel H- Pile or Spread Footings, Medium Depth Bedrock Open Steel Deck on Steel Girder Concrete Deck on Steel Girder New structure Buried Concrete Slab/Girder Buried Concrete Slab/Girder Timber Twin corrugated metal pipe culverts New structure

14 Design Options Numerous Applications Highly Customizable Geometries Spans up to 75 Single or Multiple Spans Skewed designs Standard geometries or customized for specific sites Deep soil cover (45 and greater) Water/stream crossings, Roadway overpass/underpass, Railway, Pedestrian, Tunnels

15 Structures We Like to Do - Speed & Savings Better than Traditional Materials Ownership Bridge Type Span Soil Cover Headwall Type Crossing Type Rise:Span Ratio Foundation Type Project/Award Type FRP Panel MSE or Tied Stream DOT Municipal Private Other Highway Rail Pedestrian 20 ft to 75 ft 4 ft to 15 ft Same 20 ft as to above, 100 ft or none Precast Concrete MSE, Tied, or Gravity CIP Concrete Tied or Gravity Any of the above, or none River Roadway Railway Farm Pedestrian Utility Line 15% - 50% Range of Rise:Span Spread Footings on bedrock Spread Footings on soil Piles supported abutments Design/Build Detail/Build Value Engineering Any project in need of a value-added design option AIT s product application is very adaptable and flexible to various site conditions, if your project does not fit the samples above, let our quick response team give you a price.

16 Design Options - Headwalls Multiple options to meet the Engineering, Economic, Environmental, 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

17 Summary and Quick Facts. Innovative Product Application Multifunction FRP composite tubes 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 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

18 Please contact us for more info Barry L. Raeburn EVP - COO barry@aitbridges.com (207) x 134 Daniel J. Bannon Structural Engineer dan@aitbridges.com (207) x 126