Bridge Design Innovation: Materials

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Bridge Design Innovation Materials
Construction
2006 Structures Congress St. Louis, MO May 18,
2006
By Brian J. Leshko, P.E.
For the benefit of business and people
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Agenda

• Bridge Design Innovations
• Innovative Material
• Innovative Technology
• Innovative Construction
• FHWA Funding Programs
• OTIA III Program
• Grant Applications

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• gt Bridge Design Innovations

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Bridge Design Innovations
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• To advance new technology and techniques
• Design of bridge structures
• Construction of bridge structures
• Contribute to goals of
• Cost Efficiency
• Traffic Mobility

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Bridge Design Innovations
1

• Cost savings from improved or longer life
  materials
• Reduce Initial Structure Costs
• Reduce Life Cycle Costs
• Time savings from accelerated construction
• Reduce Construction Cost
• Reduce Congestion Delays
• Reduce Traveler Inconvenience

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• gt Innovative Materials

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Innovative Material
2

• High-Performance Steel (HPS)
• High-Performance Concrete (HPC)
• Fiber-Reinforced Polymer (FRP)
• Alternate Rebar with Corrosion Resistance
• Innovative Coatings
• Innovative Cathodic Protection

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High-Performance Steel (HPS)12-Year Timeline
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High-Performance Steel (HPS)Types
2

• HPS Grade 50W
• HPS Grade 70W
• HPS Grade 100W
• Hybrid Design
• Use HPS 70W in high stressed flange locations
• Use grade 50W in webs and low stressed flange
  locations

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High-Performance Steel (HPS) Benefits
2

• Higher Strength
• 50-100 ksi
• Improved Weldability
• Higher Toughness
• Improve overall quality and fabrication
• Improved Weathering
• Atmospheric corrosion resistant

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High-Performance Concrete (HPC)
2

• Concrete made with appropriate materials
  
• superplasticizer, retarder, fly ash, slag, silica
  fume
• Combined and mixed according to a selected mix
  design
• Transported, placed, consolidated and cured to
  yield excellent performance
• high compressive strength
• high density
• low permeability
• good resistance to environment

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High-Performance Concrete (HPC)Types
2

• Very Early Strength (VES)
• Min. Strength 2,000 psi / 6 hours W-C lt 0.4
  80 Durability
• High Early Strength (HES)
• Min. Strength 5,000 psi / 24 hours W-C lt
  0.35 80 Durability
• Very High Strength (VHS)
• Min. Strength 10,000 psi / 28 days W-C lt
  0.35 80 Durability
• Fiber Reinforced
• HES (steel or poly) W-C lt 0.35 80
  Durability

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High-Performance Concrete (HPC)Benefits
2

• Cost-effective to construct
• Easy to maintain
• Competitive in value
• Innovative aesthetics
• 100-year service life

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Fiber-Reinforced Polymer (FRP)
2

• Composite materials made of fibers embedded in a
  polymeric resin exhibiting beneficial properties
• Impervious to chloride ion and chemical attack
• Tensile strength greater than steel
• 1/4th weight of steel reinforcement
• Electrically and thermally non-conductive

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Fiber-Reinforced Polymer (FRP)Types
2

• Bonded Reinforcement
• Beams
• Cable-Stays
• Deck Forms
• Deck Panels Slabs
• Prestressing Tendons
• Reinforcement Bars

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Fiber-Reinforced Polymer (FRP)
2

• Bonded Reinforcement Increased shear capacity
  of concrete beams using partial or complete
  wrapping (continuous jacket or spaced strips)
  with transversely oriented FRP.

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Fiber-Reinforced Polymer (FRP)
2

• Reinforcement Bars Alternative to steel
  reinforcement in concrete (CIP and Prestressed)
  to avoid corrosion (nonmetallic and
  noncorrosive).
• Aramid Fiber Reinforced Polymer (AFRP)
• Carbon Fiber Reinforced Polymer (CFRP)
• Glass Fiber Reinforced Polymer (GFRP)

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Alternate Rebar (non-FRP)with Corrosion
Resistance
2

• Clad Stainless Steel (75- to 100-year protection)
• Metallurgically bonded to inner carbon steel core
• Solid Stainless Steel (75- to 100-year
  protection)
• Lower strength need more compared to black bars
  
• Galvanized Steel
• Hot-dipped, Zinc-coated
• MMFX Rebar
• Microcomposite Multistructural Formable Steel

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Innovative Coatings
2

• Galvanizing
• Zinc Plating or In-Line Galvanizing Coatings
• Metalizing
• Pure metal sprayed coatings
• Paint Systems
• Overcoatings
• Epoxy Mastic Coatings

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Innovative Cathodic Protection (CP)
2

• Cathodic Protection a method for protecting
  reinforcing steel bars by using an anode system
  (either applied to the surface or embedded within
  the concrete) to maintain a non-corrosive
  state.

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Innovative Cathodic Protection (CP)Methods
2

• Galvanic self-powered and rely on the corrosion
  of the less noble anode (i.e. Zinc) relative to
  the reinforcing steel bars.
• Impressed Current energized using low voltage
  DC current to overcome the natural tendency for
  the steel to corrode.

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Innovative Cathodic Protection (CP)Types of
Systems
2

• Distributed CP Anodes
• Galvanic
• Impressed Current
• Discrete CP Anodes
• Galvanic
• Impressed Current

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Distributed CP Anodes
2

• Impressed Current Galvanic

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Discrete CP Anodes
2

• Impressed Current Galvanic

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• gt Innovative Technology

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Innovative Technology
3
Prefabrication Design and Construction
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Prefabrication Advantages
3

• Minimized traffic disruptions
• Improved work-zone safety
• Minimized environmental impact
• Improved constructability
• Improved quality
• Lower life-cycle costs

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Innovative Technology
3

• Prefabricated Bridge Elements and Systems
• Constructed at a location other than the bridges
  final location, then installed at the
  site
• Emphasis on innovative elements and systems
• FHWAs Framework for Prefabricated Bridge
  Elements and Systems
• (PBES) Decision-Making dated 12/07/05
• Flowchart for High-Level Decision One-Page
• Matrix One-Page
• Question-and-Discussion Format Detailed

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Prefabricated Bridge Elements
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• Superstructure
• Precast Deck Panels Full-depth and
  partial-depth
• Precast Barriers
• Precast Beams More efficient shapes
• Substructure
• Precast Bent Caps
• Precast Columns

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Prefabricated Bridge Systems
3

• Superstructure
• Preconstructed Composite Units
• Prefabricated Truss Spans
• Substructure
• Precast Abutments
• Prefabricated Bent Cap supported by Precast
  Column(s)
• Precast Pier(s)
• Totally Prefabricated Bridges

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• gt Innovative Construction

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Innovative Construction
4

• Accelerated Construction Technology Transfer
  (ACTT)
• Highways for LIFE (HfL)

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Accelerated Construction Technology Transfer
(ACTT)
4

• Minimizing the impact of ongoing highway
  construction on motorists and adjacent
  communities by streamlining project schedules and
  containing costs, while enhancing safety and
  improving quality.

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Accelerated Construction Technology Transfer
(ACTT)
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• Find better methods to
• get in, get it done right, get out, and stay
  out.
• 2-Day Workshop
• multidisciplinary team of national transportation
  experts works with local agency professionals to
  evaluate all aspects of the project from the
  perspective of various Skill Sets.

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Accelerated Construction Technology Transfer
(ACTT)
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• Skill Sets
• Innovative Financing / Contracting Long Life
  Pavements
• Right-of-Way / Utilities / Railroads Traffic /
  Safety / ITS
• Roadway / Geometric Design Environment
• Geotechnical / Materials Construction
• Structures Public Relations

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Accelerated Construction Technology Transfer
(ACTT)
4

• Prefabrication
• Pre-Assembly
• Incremental Launching
• Superstructure Lift-In
• Superstructure Roll-In

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Highways for LIFE (HfL)
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• Long-Lasting
• Better (1)
• Innovative
• Fast Construction Faster (2)
• Efficient and Safe Less Cost (3)
• Must have all three!
• Innovation only occurs when empowerment
  encounters need.

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• gt FHWA Funding Programs

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Innovative Bridge Research Construction
Program (IBRC)
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• Transportation Equity Act for the 21st Century
• Createdgt
• Section 503 of Title 23, Chapter V
  -Transportation Research

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IBRCProgram Information Available _at_
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http//ibrc.fhwa.dot.gov

• SAFETEA-LU Legislation Continues Program
• Annual Solicitation
• IBRC Program Guide
• Project Database
• FHWA Contacts

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Innovative Bridge Research Construction
Program (IBRC)
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Key Program Features

• Innovative materials for highway bridges
• Demonstration projects
• Performance monitoring
• RD Technology transfer

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IBRC Program Primary Goal
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Development and demonstration of
new, cost-effective,
highway bridge applications
of innovative materials
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IBRC7 Program Goals
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• New, cost-effective innovative material for
  highway bridge applications
• Reduction of maintenance costs and life-cycle
  costs of bridges, including the costs of new
  construction, replacement, or rehabilitation of
  deficient bridges

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IBRC7 Program Goals
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• New nondestructive bridge evaluation technologies
  and techniques
• Engineering design criteria for innovative
  products and materials for use in highway bridges
  and structures

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IBRC7 Program Goals
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• Construction techniques to increase safety and
  reduce construction time and traffic congestion
• Highway bridges and structures that will
  withstand natural disasters, including
  alternative processes for the seismic retrofit of
  bridges and
• Cost-effective and innovative techniques to
  separate vehicle and pedestrian traffic from
  railroad traffic.

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IBRC Eligibility
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• Funds are available for bridge projects that
  demonstrate an innovative material application
  and meet one or more of the seven program goals
  listed in Section 503(b)(2) of Title 23
• Location - the project may be on any public
  roadway
• State
• County
• City
• Road or Bridge Authority

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IBRC Eligibility
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Eligible Activities - funds available for

• preliminary engineering,
• costs of the innovative material portion of
  repair, rehabilitation or construction of bridges
  or other structures,
• costs of project performance evaluations
  including instrumentation and performance
  monitoring of the structure following
  construction

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IBRC Eligibility
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• Proprietary Products - As this is a research and
  experimental program, it is in the public
  interest that proprietary and sole source
  products may be included in the projects, but
  they must be clearly identified and described.

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IBRCSelection Criteria Considerations
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• Project demonstrates the application of an
  innovative material
• Project meets one or more of the 7 program goals
• Project incorporates materials or products which
  are readily available

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IBRCSelection Criteria Considerations
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• Design/application is repeatable and/or has
  widespread application
• Projects where Federal funds are leveraged with
  other significant public or private resources
• Projects which are ready/near ready to go to
  construction phase

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IBRC Schedule for Obligation of Funds, FY 2005
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Action FY 2005 Solicitation
4/18/2005 Submittal 7/15/2005 Fund
Allocations 11/30/2005 FY 2006 Fund
Obligations, NLT 9/30/2006 FY 2006 Letting
Dates, NLT 6/30/2007 FY 2007
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TEA-21 IBRCProgram Funding
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• Repair, Rehabilitation New Construction
• Year Authorized Available
• FY 1998-99 25 M 22 M
• FY 2000 17 M 15 M
• FY 2001-04 20 M / year 17 M / year
• FY 2005 20 M / year 17 M / year
• Research, Development, Technical Deployment
• FY 1998-03 1 M / year .87 M / year

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TEA-21 IBRCProgram Funding
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• TEA-21 funded for six years,
• FY 1998 FY 2003
• TEA-21 extended for 20 months, through May 31,
  2005
• Full funding for FY 2004,
• partial funding (8/12ths) for FY 2005

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IBRCProgram Funding
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• Secretary Determines Federal Share - may be less
  than 100 on projects with estimated cost gt 500K
  
• Funds are 100 Federal - No Matching Funds
  Required

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Number of IBRC Funded Projects by Type of
Material (FY 1998-01)
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• gt OTIA III Program

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Bridge Background InformationBaseline Reports
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• Bridge Strategy Report
• Bridge Options Report (BOR)
• Revised Bridge Options Report (2005)

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Bridge Background InformationBaseline Reports
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• Environmental Baseline Reports
• Engineering Baseline Reports
• Cost Estimate
• Crack Mapping
• Drawings
• Foundation Report
• Geology Report
• Inspection Report
• Site Photos
• Video Clips
• Existing Engineering Data
• Scoping Report

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Bridge Scoping Report
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• Review of Baseline Reports
• Bridge Recommendations
• Replace
• Repair
• Incorporate Design Innovation

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OTIA III Program Design InnovationInnovative
Materials Rapid Reconstruction
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• Innovative Bridge Research Construction (IBRC)
• High-Performance Steel (HPS)
• High-Performance Concrete (HPC)
• Precast members
• Bridge deployment
• Accelerated Construction Technology Transfer
  (ACTT)
• Get in, get out, stay out

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Approach to the Work
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• Scope of Work Definitions
• Replacement Structures
• The removal of an existing structure and
  construction of a replacement structure on a new
  alignment or using staged construction.

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Approach to the Work
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• Program Purpose Structures capable of carrying
  permit loads without
  restriction
• Repair Structures
• Perform work required to strengthen girders
  and/or cap beams -
  potential use of Innovative Materials
• Load rating ratios for all ODOT permit vehicles
  exceed 1.0
• LRFR Load Rating Method with modifications by
  ODOT

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TSL Narrative
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• Replacement Bridge Outline
• Alternatives analysis for all types not selected
• Structure type
• Span configuration
• Foundation type
• Construction staging
• Programming level structure cost
• Maintenance
• Detailed analysis of most viable alternatives
  with designation of preferred alternative
• Construction cost estimate for two alternatives

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TSL Narrative
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• Repair Structures
• Identify preferred alternative techniques after
  all repair types are considered
• Choice of repair type must consider traffic
  control mobility during construction
• Repair alternative must consider aesthetics in
  areas of high visibility
• Narrative must discuss ALL possible repair types
• Girders - internal stirrups, external
  post-tensioning, etc.
• Crossbeams (bent caps) internal stirrups,
  external post-tensioning, cap widening, infill,
  etc.

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• gt Grant Applications

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Grant Application Process
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• Identify potential technology
• Identify possible projects
• Determine costs of technology and design
• Propose grant application to State DOT
• Acceptance by State DOT
• Approval by State DOT
• Submit grant application

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Timeline for Innovation
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• January Identify technology projects,
• including
  costs
• February Meet with Technical Services
• March Begin approval process
• July Send in grant applications
• October FHWA notification of grant awards
• Following year Project construction

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Questions ????
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End
Bridge Design Innovation Materials
Construction
2006 Structures Congress St. Louis, MO May 18,
2006

• By Brian Leshko, P.E.