Accelerated Bridge Construction Methods Reline of Culvert and Small Span Bridges

New Conventional Bridge Construction Methods

North Central State Consortium – October 8, 2014

Today’s Presentation Outline

Who is CONTECH and How Can We HelpReline of Culverts

Reline of Small Span BridgesABC for Conventional Construction Methods

One free Service

Site Solutions for Bridge, Storm water, Drainage,Retaining Walls, Erosion Control, & Sanitary

Real World Savings Available with RelineNew York DOT - Trumansburg, NY

Existing Historic Stone Arch

Replace for $2,000,000 Reline for $260,000

Assemble and Slip line.

Back grout.

Structural Check HS-25 Live Load

Save $ 1.74 million !!

Popular Plastic Pipes, Innerflow - Smooth Wall HDPE, DuroMaxx, Steel Reinforced Polyethylene, A-2000 – Corrugated PVC with Smooth Interior

Round and Pipe Arch Shapes - Corrugated Metal Pipe

Galvanized Aluminized (ALT2) Aluminum Polymeric Coated Smooth Lined Metal

Aluminum Box Culvert (One of many type of Plate Options)TEXAS Department of Transportation

Saved $50,000 over replacing the bridge while still maintaining traffic flow

CON/SPAN – Three Sided Concrete Arch MRW 314 - Morrow County Ohio

Design Considerations:

1) Hydraulics2) Structural Capacity – AASHTO LRFD

3) Construction Practicality

HydraulicsInlet Control

vs.Outlet Control

End treatmentso Projectingo Mitered to conform to fill slopeo Headwallo Headwall & Wingwalls

Grout in Lifts to Prevent Pipe Floatation

2nd lift

3rd lift

1st liftGrout ports

End View

Grout

Vertical Brace

WDOT Mitchell Interchange – 54’ AL-T2 reline of Concrete Pipe - 2012

Wisconsin DOT STH 16, Pewaukee, WIPolymeric Smooth-Cor Pipe Arch - 2012

Illinois DOT I-74, Moline, Illinois144” Polymer Smooth-Cor Pipe Arch - 2013

MnDOT – Rat Creek – Reline of concrete box under 20’ of cover - 2000

2-Flange Tunnel Liner Plate - Coatings

Galvanized Steel Uncoated “Black” Steel

Aluminized Steel Type 2 Aluminum Alloy

MINNESOTA DOT – RAT CREEK - RELINE OF EXISTNG 10’ X 10’ FAILING CONCRETE BOX CULVERT under 20’ cover

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Staging of 2-Flange Tunnel Liner Plate Material. Each individual plate can be handled without equipment.

Channels placed in existing concrete floor. Assembly of Plates inside RCB. Plates are bolted together circumferentially and longitudinally .

Assembly of Tunnel Liner Plate Arch

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Tunnel Liner Plate Arch 14-years after construction

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

MNDOT Project 5205-31 Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate - 2013

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Two Harbors, MN 2 – 13’ span 2-Flange Tunnel Liner PlateState Aid Project 38-620-06, Bridge 92774 - 2006

CSX Southern, IL Bridge QSD 97.77 – Tunnel Liner Plate Reline - 2014

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MNDOT State Aid 118-130-005, Duluth, MN2nd St and 13th Avenue over Chester Creek - AL-T2 Flange Liner Plate Arch - 2012

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Rocksylvania Ave over Rock Run Creek , Hardin Co, Iowa Falls, Iowa 8’7” span X 4’2” rise O.D. 2-Flange Tunnel Liner Plate - 2013

Iowa DOT , Hwy 136 N of US 67, Clinton IA 14’9” Span X 7’9” Rise Tunnel Liner Plate Arch - 2010

Main Street Tunnel – Lisle, Illinois 11’2” X 5’8” Tunnel Liner Plate Arch - 2013

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Fond Du Lac, WI – 28’ span Bridge Cor reline of CN Rail Road Bridge - 1999

MULTI-PLATE®

Aluminum Structural PlateAluminum Box CulvertSUPER-SPAN™SUPER-PLATE® BridgeCor™

CON/SPAN® BEBO®

Continental® Bridges (Pedestrian)

Steadfast EXPRESS (Pedestrian)

U.S. Bridge (Vehicular)

Plate, Precast & Truss

MULTI-PLATE Super Span Horizontal Ellipse - 33’ Span X 20’ RiseSlip Line of Old Concrete Bridge – Davis CO, IA Highway 2

Before After

Construction Plans

Traffic Continues on Highway During Construction whichEliminates Road Close Time

Photos during the construction process.

Project Under ConstructionBackfilling around new structure

Bridge Deck Left in PlaceVoids of bridge filled with grout

No Bridge Deck Means; No deck freezing in winter, no deck maintenance, & wider shoulder for safe traffic

OHIO DOT Dayton Road - Clark County, Ohio CON/SPAN Reline of Concrete Bridge

OHIO DOT Dayton Road - Clark County, Ohio CON/SPAN Reline of Concrete Bridge

OHIO DOT Dayton Road - Clark County, Ohio

CON/SPAN Reline of Concrete Bridge

OHIO DOT Dayton Road - Clark County, Ohio

CON/SPAN Reline of Concrete Bridge

Express Foundations for ABC

Express Foundations loaded off the truck

Express Foundations ready for Aluminum Box Culvert

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EXPRESS Foundations

Filled with CIP Concrete

22’9” Span X 5’4” Rise Aluminum Box Culvert

ALBC on Express Foundation ready for grout fill

Concrete is poured in void space of the Express Foundation

Finished Project – Culvert under Trunk Highway

One year after installation

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Pleasant Prairie, WI – Park and Ride 2014 – ABC!Structure 1 – Precast CON/SPAN on Express Foundations

Express Foundations Delivered on a Flat Bed Trailer

Express Foundations Lifted into Place

Connecting wing wall footing

Setting CON/SPAN Precast Structures

CON/SPAN with Express Foundations One week after start of placing Express Foundations

Pleasant Prairie, WI – Park and Ride 2014 – ABC!Structure 2 – Truss Bridge on Express Foundations

Express Foundations Set

Lifting Abutment Wall into Place

Abutment sitting on Express Foundation

Placing Abutment Wing Wall – Front Side Photo

Abutment wall – Rear Side Photo

Pouring Concrete in Express Void Space

Steel Truss Bridge – One week after Construction Start

Truss Bridge Cost – 55k, Express Foundation 59K

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Water applications

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