North Central State Consortium – October 8, 2014 Accelerated Bridge Construction Methods Reline of Culvert and Small Span Bridges New Conventional Bridge Construction Methods

Today’s Presentation Outline Who is CONTECH and How Can We Help Reline of Culverts Reline of Small Span Bridges ABC for Conventional Construction Methods One free Service

Site Solutions for Bridge, Storm water, Drainage, Retaining Walls, Erosion Control, & Sanitary 3

Reline for $260,000 Replace for $2,000,000 Real World Savings Available with Reline New York DOT - Trumansburg, NY Existing Historic Stone Arch Reline for $260,000 Replace for $2,000,000

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 There are several different types of CMP each has different physical characteristics and recommended environments. There are several other types of CMP such as Aluminized, Aluminum and Poly Coated that can give you a 75 to 100+ year life span depending on the gage and environment. The pipe we put in today is not the same pipe you may be relining.

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 With 134 different sizes, Aluminum Box Culvert offers a low profile shape great for reline old concrete box culverts and short span bridges.

CON/SPAN – Three Sided Concrete Arch MRW 314 - Morrow County Ohio Con Span provided a quick cost effective solution that was installed in a day. (footings and back grouting took additional days)

Design Considerations: 1) Hydraulics 2) Structural Capacity – AASHTO LRFD 3) Construction Practicality

Hydraulics Inlet Control vs. Outlet Control When designing a structure hydraulically, two flow scenarios must be checked. They are inlet control and outlet control. Each scenario has a unique set of factors that affect the performance of the culvert. With inlet control - the pipe can carry more water than the inlet can actually let in so the limiting primary factors are the end area and the geometric characteristics of the inlet. With outlet control - the inlet can let in more water than the pipe can carry so various factors beyond the inlet end come in to play in the flow characteristics of the structure. Which of the structures shown are likely to be an inlet controlled structure? (the ALBC) What mode of flow is the UF storm sewer likely operating under? (outlet control) 14

End treatments Projecting Mitered to conform to fill slope Headwall Headwall & Wingwalls End treatments are important input considerations during hydraulic design of culverts and small bridges. Many times hydraulics can be greatly improved by improving the existing inlet of the pipe.

Grout in Lifts to Prevent Pipe Floatation 3rd lift Grout Vertical Brace Grout ports 2nd lift The number and frequency of grout ports vary depending on the size and length of pipe as well as the fluid nature of the grout. 1st lift End View

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

Wisconsin DOT STH 16, Pewaukee, WI Polymeric Smooth-Cor Pipe Arch - 2012 The pipe doesn’t have to be dry to install the reline culvert. The Poly coating will give this new pipe a 100+ year service in most environments.

Illinois DOT I-74, Moline, Illinois 144” Polymer Smooth-Cor Pipe Arch - 2013 The pipe doesn’t have to be dry to install the reline culvert. The Poly coating will give this new pipe a 100+ year service in most environments.

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

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

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

Assembly of Tunnel Liner Plate Arch

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

. Two Harbors, MN 2 – 13’ span 2-Flange Tunnel Liner Plate State Aid Project 38-620-06, Bridge 92774 - 2006 The relining process with Tunnel Liner Plate allows the historical nature of this structure to stay in tact. We can make many unique shapes out of our plate products that can be easily installed by multiple contractors. In most cases special equipment is not required.

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

MNDOT State Aid 118-130-005, Duluth, MN 2nd St and 13th Avenue over Chester Creek - AL-T2 Flange Liner Plate Arch - 2012

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

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

Plate, Precast & Truss MULTI-PLATE® Aluminum Structural Plate Aluminum Box Culvert SUPER-SPAN™ SUPER-PLATE® BridgeCor™ CON/SPAN® BEBO® Continental® Bridges (Pedestrian) Steadfast EXPRESS (Pedestrian) U.S. Bridge (Vehicular) As you can see, Contech truss bridges are just a segment of the overall Contech bridge. Just like pipe, Contech has a variety of Bridge Systems to choose from for almost any application. What system best fits my application? The answer depends on a number of different site constraints, but most times the best place to start is with the overall bridge span required. At first glance, you may be overwhelmed with all of our bridge options. When do I use Plate…When do I use Precast…When do I use Truss? The type of system will depend on your specific project needs, one place to start is working by with your local Project Consultant, who can help evaluate your site and assist in structure selection. Here are the span ranges for each bridge type: Plate ranges from 5 ft. to 52 ft. Precast from 12 to 102 ft. Pedestrian trusses will take you to 250 ft. using a conventional truss design. For spans longer than 250’, we use a cable stayed design. Vehicular steel truss bridges can span up to 300’ with the Thru Truss offered by our partner, US Bridge. These are all single spans – if you have a larger flow or the need a larger span, you can use any of our structures in multiple span arrangements. Also, notice that we have a lot of overlap with our bridges. Which is why I suggest you work with your local Project Consultant to help identify the best fit for your project. Next Slide

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

Construction Plans

Traffic Continues on Highway During Construction which Eliminates Road Close Time

Photos during the construction process.

Project Under Construction Backfilling around new structure

Bridge Deck Left in Place Voids 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 Concrete channels cast and doweled into existing structure.

OHIO DOT Dayton Road - Clark County, Ohio CON/SPAN Reline of Concrete Bridge Quick installation only taken 1 day in many cases for small bridge replacements. Many times rollers or come longs are used to get the concrete pieces into place.

OHIO DOT Dayton Road - Clark County, Ohio CON/SPAN Reline of Concrete Bridge With the precast headwalls and wing walls the bridge can be made wider and safer for traffic. Combinations of standard fill and grout commonly done to make the reline more cost effective and quicker to install.

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

Express Foundations for ABC

Express Foundations loaded off the truck

Express Foundations ready for Aluminum Box Culvert

22’9” Span X 5’4” Rise Aluminum Box Culvert Filled with CIP Concrete EXPRESS Foundations

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

Pleasant Prairie, WI – Park and Ride 2014 – ABC 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 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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