Larry Abatiell, PEExecutive Vice President

Sales, Marketing and Business Development

Larry@aitbridges.commobile 1-978-388-5600

AIT Composite Arch Bridge System

Presentation Outline

Presentation Outline1. History and Our Capabilities2. Introduction to Arch Bridges3. Introduction to Composites4. Composite Arch Bridge System5. Manufacturing6. Installation7. Product Solutions 8. Summary / Q & A

GOAL OF THE PRESENTATION:Introduce you to the award winning AIT Composite Arch Bridge System and highlight why it is a Innovative option for new or replacement bridge projects.

• UMaine Research Center• 87,000 ft2 facility• Researching Hybrid Composite

Systems since 1996• 10+ years development of the

Composite Arch Bridge System

AIT / University of Maine – Focused on Innovation

Secretary of Transportation Ray LaHood Speaks about the Composite Arch Bridge System at UMaine Press

EventComposite Arch Bridge

System Structural Testing

AIT Bridge Systems

• AIT has become an industry leader in innovation with numerous awards. The core product, formally known as Bridge-in-a-Backpack, was developed to address the need for a more durable, easy to construct, lower maintenance, corrosion-free bridge.

History and Our Capabilities

Featured in: ENR, Concrete International, Popular Science, Popular Mechanics, NY Times…

National Recognition

2011 Engineering Excellence Grand Award

2011 Charles Panko Award for Innovation

2010 Award for Composites Excellence Most Creative Application

2011 TIG Focus Technology

AIT Bridge Systems – We provide a “High Performance” BridgeWe supply highly durable composite materials which includes our custom designed arch tubes and composite decking.

The “Whole” High Performance Bridge System

Structurally Efficient – The Arch Advantage Durable – Low Life Cycle Costs Cost-effective Sustainable / Environmentally Friendly Secure / Safe – AASTHO Approved Aesthetic Pleasing Functional Innovative

• We offer design and optional services to support our “Whole” bridge design Free services that help with Identification, Screening and Selection process. Foundations, Structural Design, Headwalls and Wing Wall Design Inspection and Installation Services Financing

History and Our Capabilities

Introduction to Arch Bridges

•History of Arch Bridges•Early concrete arch bridges were governed by building traditions of their predecessor, the stone arch built by the Romans in 800BC.•Daniel Luten patented the first concrete arch in US in 1894. He was a graduate of the University of Michigan. He over 700 earth-filled and arch-girder bridges before 1907.•The earth-filled arch is one of the most structurally efficient bridge types in our inventory.•After the girder bridges, arches are the second oldest bridge structures and is considered one the classic aesthetic shapes in the world.

•Advantages of traditional arch bridge designs•No approach slabs or concrete decks providing superior long-term performance •Efficient in compression•Aesthetically pleasing•Safe / Secure•Flexible designs •Environmentally pleasing

•Challenges of traditional arch bridge designs•Tension forces•Thrust forces need to be considered at the foundation •Early arches requires extensive formwork for construction•Reduced waterway area

9

What is a Composite Material?

A broad definition of composite is: Two or more chemically distinct materials which when combined have improved properties over the individual materials. Composites could be natural or synthetic.

• Wood is a good example of a natural composite, combination of cellulose fiber and lignin. The cellulose fiber provides strength and the lignin is the "glue" that bonds and stabilizes the fiber.

• The ancient Egyptians manufactured composites! Adobe bricks are a good example. The combination of mud and straw forms a composite that is stronger than either the mud or the straw by itself.

• Bamboo is a very efficient wood composite structure. The components are cellulose and lignin, as in all other wood, however bamboo is hollow. This results in a very light yet stiff structure. Composite fishing poles and golf club shafts copy this natural design.

10

Composites - Used Any place where high performance materials are desired

• In the United States, composites manufacturing is a 25 billion dollar a year industry. There are about 6000 composites related manufacturing plants and materials distributors across the U.S. The industry employs more than 235,000 people. An additional 250,000 people are employed in businesses that support the composites industry, including materials suppliers, equipment vendors, and other support personnel.

• FRP in the bridge sector have been one of the slowest growth segments

11

Composites – Polymer Matrix

Polymer matrix composites (PMC) and fiber reinforced plastics (FRP) are referred to as Reinforced Plastics. Common fibers used are glass (GFRP), graphite (CFRP), boron, and aramids (Kevlar).

Matrix materials are usually thermoplastics or thermosets; polyester, epoxy (80% of reinforced plastics), fluorocarbon, silicon, phenolic.

Advantages of composites

• Advantages of Composites

– Customized mechanical properties– Customized shapes– High strength-to-weight ratio– Corrosion resistance– High fatigue life– High stiffness-to-weight ratio– Wear resistance– Chemical resistance– Thermal insulation– Many manufacturing options

Composite Arch Bridge System

An innovative arch system for bridge construction that combines high-performance composites and cast-in-place concrete to create an efficient and economical soil-structure interaction system.

What are Composite Arches?

• Combination of carbon and glass fibers in a vinyl ester resin

• Manufactured in the United States or can be done locally by “certified” producers

• Mass-produced to high-quality standards

Three Functions of the FRP Arch Tube

1. Stay-in-place form for concrete

Arches and decking are the only formwork needed to stabilize the

structure

Temporary Formwork for Arches Concrete Engineers Handbook,

McGraw-Hill, 1918

Eliminates need for temporary formwork

2. Structural reinforcement for concrete

Eliminates need for rebar installation,Enhances concrete performance

Three Components of FRP Reinforcement Confined concrete demonstrates significant ductility over unconfined

Confined

Unconfined

Three Functions of the FRP Arch Tube

3. Environmental protection for concrete

Reduces bridge maintenance requirements

Concrete Corrosion Cycle

Steel rusts and expands causing concrete spalling

Spalling concrete exposes more reinforcement

Three Functions of the FRP Arch Tube

What is Composite Decking?

• AIT Bridge Systems developed a composite decking product. The decking uses advanced composite materials to create a durable, strong, corrugated FRP deck. This robust decking efficiently supports traffic and earth loads.

Composite Arch System: Manufacturing

Primary rigidification:Inner bladder is inflated to define cross section

Straight tube is secured to arch formwork

Composite Arch System: Manufacturing

• Primary rigidification:

• Resin infusion – Vacuum Assisted Resin Transfer Molding (VARTM)

Composite Arch Production Process

1. Tubes assembled/packaged2. Inflate tubes3. Bend around arch form4. Infuse with resin

System components can be mass-produced for multiple design options

Manufacturing of a 15” diameter 48’ span composite arch

Arch Formwork

Arch Delivery/Unloading

• AIT’s arches arrive on site ready for installation

• Can be unloaded quickly with hand labor

• Minimizes heavy trucking• No heavy equipment

required HEAVY TRUCKS

Placing the Composite Deck

Arch Concrete Filling

• Filled with Self Consolidating Concrete (SCC)• Simple procedure, no rodding/vibration required• AIT provides standard specifications for concrete

mix

Pumping concrete into arches Funnel boxes direct flow, prevent overflow

Step 5: Fill Arches with ConcreteAIT Composite Arch Bridge Construction Sequence

75mm

Step 5: Fill Arches with ConcreteAIT Composite Arch Bridge Construction Sequence

Step 5: Fill Arches with ConcreteAIT Composite Arch Bridge Construction Sequence

Step 5: Fill Arches with ConcreteAIT Composite Arch Bridge Construction Sequence

Backfill and Compaction

After arches are filled with SCC, headwalls and wingwalls are erected, and the bridge is backfilled

Step 7: Backfill Bridge with SoilAIT Composite Arch Bridge Construction Sequence

Step 7: Backfill Bridge with SoilAIT Composite Arch Bridge Construction Sequence

Arch Headwall Options

Highly Customizable Geometries

•Spans up to 65 feet

•Single or Multiple Spans

• Skewed designs up to 45°

• Standard geometries or customized for specific sites

• Soil cover up to 45’

• Rail, streams, roadway and tunnel

AIT Product Solutions

Versatile system can be applied to a wide range of bridge geometries/site conditions

Single-radius arches with rise/span from 15%-50% Variable radius arches in standard sizes up to 48’ span

Single-span and multi-span structuresSkewed bridges reduce right of way requirements

AIT Product Solutions

AIT Cost SavingsEdmunds Township, Maine

• AIT is 50% the cost of precast (Engineering and Materials supplied to jobsite)• AIT is 40% the area of precast• AIT can build the bridge in one phase without disturbing the flow of traffic on the existing structure• AIT disturbs nearly 1000 square feet of natural stream bank less than precast

Edmunds Township, MaineSpan Rise Width # of Phases Bridge Area Undisturbed Stream Bank Cost

Precast 56 ft 13 ft 100 ft 2 5600 sf 0 sf $ 750,000.00 AIT Bridges 51 ft 11 ft 43 ft 1 2200 sf 950 sf $ 398,000.00

Summary & Opportunities

• Composite Arch Bridge System – We provide a High Performance “Whole” Bridge Design– Innovative arch system for short-to medium-span bridge construction– Cost-Effective - Fast and simple to construct; Minimal transportation

and equipment needs– Durable – long life and minimal maintenance– Enhanced innovative material performance makes for safe,

functional, and sustainable structure

• AIT Bridge Systems offers:– An fully engineered bridge system

uniquely tailored to fit your needs – Composites offer the lowest life- cycle

costs in the industry with a design life of (100+years)

www.aitbridges.com

Summary & Opportunities

• Can use existing substructures or leave in place and span over

• Weighs less than precast-less concrete

• Can be constructed out of the water-ease of permitting

• Minimal utility adjustments-no overhead work

• Fast assembly-Fast fabricate and deliver

• AASHTO approved

• Exceeds most performance based specifications

• Minimal/no maintenance, Warrantee, Maintenance and annual inspection is available.We stand behind our product

www.aitbridges.com

Thank youQuestions?

Larry Abatiell, PEExecutive Vice President

Sales, Marketing and Business Development

Larry@aitbridges.commobile 1-978-388-5600