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

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What & How? 2.

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Design options Overview of recent projects 4.

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Specific project details Performance tested in Lab AIT’s services “ How can we work with you? ”

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

Projects Completed & Underway

Status

Complete (7)

Bridge Location/Name

Description

Pittsfield, ME – Neal Bridge

Pilot Project with University of Maine

Anson, ME – McGee Bridge

Municipal Design/Build Project

Bradley, ME – Jenkins Bridge

Maine Composite Bridge Initiative

Auburn, ME – Jenkins Bridge

Maine Composite Bridge Initiative

Belfast, ME – Perkins Bridge

Maine Composite Bridge Initiative

Hermon, ME – Tom Frost Memorial Bridge

Snowmobile/Pedestrian Bridge

Fitchburg, MA

MA DOT Accelerated Bridge Program Under Construction (2)

Caribou, ME – Farm Access Overpass

Maine Composite Bridge Initiative

Pinkham’s Grant, NH

State Bridge Program Design & Proposal Bridges in design in ME, MI, proposals submitted in 11 states

Const.

Year

2008 2009 2010 2010 2010 2010 2011 2011 2011

Key Stats

29.0’ Span 23 Arches 28.0’ Span 9 Arches 28.5’ Span 14 Arches 38.0’ Span 13 Arches 48.0’ Span 16 Arches 44.5’ Span 3 Arches 37.5’ Span 15 Arches 54.0’ Span 22 Arches 24.5’ Span 6 Arches

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

Headwall Options for Test-Level 4 Design

• Wall-mounted Barriers – Precast or CIP Gravity Wall – Precast Panel MSE Walls

McGee Bridge Replacement Example – 28’ Span

CONSTRUCTION SEQUENCE

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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

A note on footings

Steel H-piles Spread Footings Royal River Bridge, Auburn, ME Perkins Bridge, Belfast, ME

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

Caribou Connector Bridge

Caribou Connector Bridge

How we got here- “Bridges to the future, now”

Maine’s Composites Initiative

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Six bridges in two years

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Variety of bridges to best gage how system fit’s into Maine’s bridge inventory

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28 55’ spans

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Stream/road crossing

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Foundation types Headwall designs Also being used in:

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Massachusetts

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New Hampshire

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Michigan

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Proposals in 11 states & 3 countries outside the US

FHWA’s Public Interest Finding:

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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

Performance Testing: Arch Testing

Load-Deflection Response of Concrete-Filled FRP Tubular Arch

80 70 60 50 40 30 20 10 0 0 1 2

HL-93 Design Load Equivalent

3 4 5 6

Vertical Deflection at Crown (in)

Initial Static Test to Failure 7 Post-Failure Behavior 8 9 10

National Recognition for Bridge-in-a-Backpack

AASHTO TIG - 2011 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

Summary and Quick Facts on CFFT Arch Bridges

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

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

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