M-25 over Harbor Beach Creek

M-25 over Harbor Beach Creek Bridge to Culvert Replacement $1.27M Programmed Cost $270,000 Innovative Bridge Research and Deployment Program Federal Grant M-25 bridge over Harbor Beach Creek in Huron County is in poor condition and is scour critical. This project received $270,000 in federal funds from the Innovative Bridge Research and Deployment (IBRD) program from FHWA. Existing Harbor Beach Creek Bridge

M-25 over Harbor Beach Creek Composite Arch Culvert System aka “Bridge in a Backpack” Composite Arch Culvert (CFRP) – Made from concrete filled Carbon Fiber Reinforced Polymer tubes Bridge in a Backpack – so named because it’s basically carbon tubes folded up that can be carried in duffel bags. Then they are inflated and shaped into arches, infused with resin and easily placed in position without heavy lifting. The arches are covered in composite deck and filled with concrete. Then covered in gravel and the road section is built on top. Because there is no rebar or exposed concrete, the maintenance costs are reduced and could extend the life of the structure. Designs for single span from 25’-70’ and multi-span designs exceeding 800’.

“Bridge in a Backpack” Arches inflated and formed Composite decking Carbon fiber reinforced polymer is placed over air bladder. The bladder is then inflated and placed on a form of the desired geometry and infused with resin. This forming and infusion can be performed in a shop or in the field. Arches can be placed in a day with a small crane and hand labor and act as stay-in-place form and external reinforcement. Composite decking attached with screws. The superstructure can be placed in 2 weeks. FYI: Hollow arch weight for 12” dia 50’ span is about 200 lbs, 22’ span is about 70 lbs. Two men can lift and adjust arches to final position, roughly 2’ apart. Composite decking Installing arches

“Bridge in a Backpack” Filling arches with concrete Backfill to road Here the arches are filled with Expansive Self-Consolidating Concrete. Cons: still need to drive piles need pre-bid meeting with contractors to discuss the Expansive Self-Consolidating Concrete (contractors unfamiliar with in Michigan) The manufacturer will have technical representatives available to assist in construction oversight for 6 days. Backfill to road Fascia

M-25 over Harbor Beach Creek Traffic currently detoured Fix Life of >75 years Every Day Counts Faster + Cheaper + Safer + Smarter = Better Existing Harbor Beach Creek Bridge Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER

M-25 over Harbor Beach Creek Started in Spring 2012 Original completion date August 25 Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Sixteen 12” diameter arch tubes arriving at project site

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Arch end section Inlet holes for concrete

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Large lateral forces from arches required battered piles First arch rib install

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Reinforcement for arch end anchoring into abutment Multiple arch tubes installed

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Arch tube installation complete Finishing concrete around arch tube endings

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Composite decking installation

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Expansive Self Consolidating Concrete (SCC) slump flow test Measuring slump flow

M-25 over Harbor Beach Creek Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER Filling arches from top with SCC Sounding for voids – 8/9

M-25 over Harbor Beach Creek Challenges: Still need a conventional deep foundation Remote project location, readi-mix supplier 1 hour away Issues with SCC remaining fluid and workable long enough Concrete setting too fast in arch ribs causing voids Working with AIT to resolve issues: Revising SCC mix with additional admixtures Drilling additional holes in arch ribs to fill voids with grout Identify high stress areas via finite model to avoid drilling in those locations Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER

M-25 over Harbor Beach Creek When arches complete and composite with concrete, a 7” concrete overlay will be cast over the composite decking for lateral stability Decorative composite finish will be placed on headwalls and wingwalls Placement of roadway fill and pavement section Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER

M-25 over Harbor Beach Creek Design specifications recently voted on and approved by AASHTO Subcommittee on Bridges and Structures Progress Clause says May 14 start to Aug 25 open to traffic. 13.3 mile detour – 14.47 min 4.7 mi work zone – 5.07 min Difference/delay – 9.4 min Coordination between Lansing Bridge (Feuerstein), Region Bridge and TSC Every Day Counts prefab bridge structures & elements FASTER: Yes, compared to a bridge type structure – by 6 weeks CHEAPER: Yes, compared to a bridge. Yes, when looking at future maintenance costs. Yes, smaller equipment for installation and less smaller transport costs. (If innovation is utilized more the price will come down, approximately 2/3 price of conventional, mostly in time savings and maintenance) Conventional bridge – concrete overlay in 25 yrs = $80,000 HMA overlay in 10 yrs and again at 20 yrs = $12,000 SAFER: Less maintenance means safer for workers. SMARTER: Yes, lower carbon footprint during construction (smaller equipment needed to build) 1/3 less carbon footprint of a typical concrete bridge ¼ less carbon footprint of a typical steel bridge = BETTER

Technical Committee T-6 Austin, TX, July 9, 2012 MDOT CFRP Implementation: Building bridges for the 21st century AASHTO Subcommittee on Bridges & Structures Technical Committee T-6 Austin, TX, July 9, 2012 Matt Chynoweth, Engineer of Bridge Field Services

MDOT CFRP Deployment Pembroke over M-39 Bridge Replacement Existing Structure Two span simply supported prestressed I-beam structure in poor condition (based on NBIS ratings) 19

MDOT CFRP Deployment Pembroke Bridge CFCC cables Materials stored at Detroit Maintenance Garage through winter and spring of 2011 20

MDOT CFRP Deployment NEFMAC Grid installation Special provisions for handling instructions were written for installation 21

MDOT CFRP Deployment NEFMAC Grid installation Finished installation 22

MDOT CFRP Deployment Monitoring and Data Collection Measuring deck deflections, deck strains and PT tendon loads 23

MDOT CFRP Deployment Complete Pembroke Structure Photos taken October 2011 24

MDOT CFRP Deployment M-50/US-127 BR over NS RR Existing structure Project let January 2012 25

MDOT CFRP Deployment M-50 Bridge CFCC cables Cables were double sheathed and fed into 5” conduits 26

MDOT CFRP Deployment M-50 Bridge CFCC cables Cables were double sheathed and fed into 5” conduits 27

MDOT CFRP Deployment M-50 Bridge CFCC cables Fabricator’s stressing chair: cables stressed to 75 kips, then 150 kips once deck is placed & cured 28

MDOT CFRP Deployment M-50 Bridge CFCC cables Load cells placed on dead end measure micro-strain, which is converted to force 29

Stirrups Configuration of Control decked Bulb T Beam Transverse ducts for TPT Steel/CFRP stirrups along the span Steel/CFRP stirrups at diaphragms Steel/CFRP prestressing strands

Other research: MDOT project OR14-24: Evaluating Long Term Capacity and Ductility of Carbon Fiber Reinforced Polymer prestressing and post tensioning strands subject to long term losses, creep, and environmental factors To begin in FY 2013 NCHRP 12-97: Design Guidelines for Field Deployment CFRP prestressed beams in Bridge Construction MDOT submitted research idea Next Steps 31

Thank you Questions?