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FRP Composites for Bridge Decks and Superstructures: State of the Practice in the U.S. Jerome S. OConnor, PE, F-ASCE MCEER Sr. Program Officer, Transportation.

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Presentation on theme: "FRP Composites for Bridge Decks and Superstructures: State of the Practice in the U.S. Jerome S. OConnor, PE, F-ASCE MCEER Sr. Program Officer, Transportation."— Presentation transcript:

1 FRP Composites for Bridge Decks and Superstructures: State of the Practice in the U.S. Jerome S. OConnor, PE, F-ASCE MCEER Sr. Program Officer, Transportation Research, University at Buffalo FRP COMPOSITES FOR INFRASTRUCTURE APPLICATIONS 2011

2 Pedestrian Bridges /- in USA 2.80% by E.T.Techtonics, 20% by others 3.Bridge Cost ~ $60 / SF 4.AASHTO Guide Spec

3 Bridge of the Future Long life Long life Less $ Less $ Fast Fast Minimal maintenance Minimal maintenance Shock resistant Shock resistant Adaptable Adaptable (Reduced carbon footprint) (Reduced carbon footprint)

4 Some Advantages Light weight (high strength-to-weight ratio) Light weight (high strength-to-weight ratio) Corrosion resistant Corrosion resistant Chemical resistant Chemical resistant High tensile strength High tensile strength Fatigue resistant Fatigue resistant Potential for good, consistent quality Potential for good, consistent quality Steel bridge beam

5 PAST

6 FRP Decks/SS by Method of Manufacture

7 FRP Decks/SS by Manufacturer Hardcore, Martin, Creative, Strongwell, Wagner, Bedford, Hillman, Composite Advantage, MFG, Webcore, ZellComp

8 # FRP Decks by State (73)

9 # FRP Superstructures by State (48) Note: Maine includes glu-lam with composites

10 History 68% used IBRC or other special funding ½ the projects were new construction FRP decks were attached to steel stringers (95%), concrete girders, FRP beams Largest deck area = 11,970 SF Highest traffic volume = 30,000 vpd Cost per SF is 2 to 3 x cost concrete deck (>$75/SF) – Low E leads to use of more material (and expense) just to meet deflection criteria. Weight can be psf vs. >100 psf for concrete

11 Design Considerations There is no AASHTO spec for FRP design Design is deflection driven because of low stiffness resulting from low E Keep LL+DL stresses <20% of ultimate to avoid brittle failure (although there may be pseudo-ductile behavior) Avoid creep by keeping DL stresses <10% of ult. Provide UV protection Think thru haunch & connection details Thermal stresses can exceed LL stresses Nov 13, :30 am

12 Details Scuppers Curbs Connections Cross slope Haunch Cut-outs Also: Railing Wearing surface

13 PRESENT

14 Replace Heavy Decks Before After

15 Replace Light Decks South Broad Street over Dyke Creek, Wellsville, NY Oct Hardcore Composites

16 Maintain Historic Structures NY Route 418 over Schroon River, Warrensburg, NY Nov Martin Marietta Composites

17 Fast Installations Accelerated bridge construction in high traffic areas enhances safety Rte. 248 over Bennetts Creek Rexville, NY Sept Hardcore Composites

18 Reduce Seismic Vulnerability Schuyler Heim Bridge, Long Beach CA Martin Marietta Composites

19 Moveable Bridges Lewis & Clark Bridge, OR Martin Marietta Composites

20 PRESENT – case studies of some issues

21 Case Study 1 NY 248 / Bennetts Creek opened 1998

22 Sample Temperature Gradient Temperature readings at 248 / Bennetts Creek 6/1 BIN

23 Sample Temperature Gradient POSSIBLE RESULTS: 1) Panel can hog; 2) High thermal stresses Time Bottom skin temperature in °F Top wearing surface temperature in °F (black color) Difference 7:30 AM :00 AM :30 AM :00 AM :30 AM :00 AM :30 AM :15 AM :00 PM :00 PM Temperature readings at 248 / Bennetts Creek 6/1 BIN

24 Tap Test of Epoxy Injection Repair Tap test before repair

25 Attempted patch of epoxy wearing surface Surface moving

26 De-bonded Sandwich Section and Water Intake (2009) Video

27 Insufficient wet-out of fibers Video 248 debonding of top faceskin

28 Case Study 2 NY367 / Bentley Creek opened 1999

29 Wearing Surface Cracking

30 Wearing Surface Debonding First winter (~ 2000)

31 Wearing Surface Debonding NY367/Bentley March 2009

32 Thermal Compatibility Issues

33 Case Study 3 South Broad St. Wellsville, NY 1.Wearing surface was replaced with asphalt. 2.Pick point required repair.

34 Case Study 4 King Stormwater Channel, CA Delamination & deterioration of top faceskin

35 illustrated here - 3 removed from service _____ 114 doing fairly well

36 THE FUTURE

37 Acciona (contractor w in-house R&D) Spain

38 U. Maine Bridge in a Backpack

39 ZellComp No field adhesives

40 Composite Advantage Infused 3D fabrics decks superstructure

41 U. at Buffalo Hybrid Efficient hybrid section

42 Wagner Australia Hybrid section Concrete surface

43 Prototype Wearing Surface developed for NYSDOT by R. Aboutaha at Syracuse University Performance Objectives Permanent bond Skid resistance, durability, protection of FRP 3/8 Polymer Concrete (for bond) FRP deck surface 1 Polymer Modified Concrete (for wear)

44 Thank you! Louis N. Triandafilou. Team Leader, FRP Virtual Team Federal Highway Administration Phone: (410) Fax: (410) Jerome S. OConnor Senior Program Officer University at Buffalo Phone: (716) Fax: (716)


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