The World’s First Thermoplastic Bridges made of Recycled Plastics John S. Kim, PhD, PE, Senior Professional Associate, Parsons Brinckerhoff October 10, 2013

U.S. Highway Bridges 600,000 highway bridges in U.S. One third of them built immediately after World War II The use of deicing material Increased traffic volume and weight Structurally deficient or functionally obsolete

Bridges in Trouble $229 billion bridge issue When people in ties and suites frequently appear under the bridges, it means a serious business! 60 percent of 600,000 US highway bridges are short-span bridges.

Why Recycled Plastic? Plastic waste: global issue 100 million tons each year worldwide Hard to degrade Recycled plastics are hardly reused. Enhanced properties from constant R&D Collective efforts for green solutions Governments’ incentives on the use of green products

From Wasteful to Useful

Thermoplastic Composite Recycled Plastic Immiscible Polymer Blend High Density Polyethylene with Polystyrene or Polypropylene coated glass fibers 6

Product Advantages Green Product (Recycled Plastic) No Corrosion, Rotting or Insect Infestation Reduced Landfill Dumping Good Toughness Characteristics No Chemical Additives Green House Gas Savings Reduced Maintenance Sustainable & Durable Cost Competitive: Initial and Life Cycle 7

Thermoplastic Properties Weight: 55pcf (Wood: 60pcf; Concrete: 150pcf; Steel: 490pcf) Specific Gravity: 0.85 – 0.90 Elastic Modulus: 350,000 psi Allowable Flexural Stress: 600 psi (Ult. = 3,000 psi) Allowable Compressive Stress: 600 psi (Ult. = 2,500 to 4,300 psi) Allowable Shear Stress: 350 psi (Ult. = 1,500 psi) Coefficient of Thermal Expansion: 0.0000282 in/in/deg F

Typical Stress/Strain Curve

Design Considerations Ultraviolet Degradation: Less than 0.003 inches/year (in full sun exposure) Moisture Absorption: Virtually impervious, retains properties in humid and wet environments Thermal Resistance: Heat deflection temperature is 125 deg C and material viable to -125 deg C Environmental Resistance: Resistant to attack by marine borers, insects, rot and corrosion Acid Resistance: Resistant to most acids and salts

Design Considerations (Cont’d) Creep: High Factor of Safety with respect to Ultimate Stress lowers creep considerably Abrasion: Highly Resistant to salts and sand occurring in Marine environments Skid Resistance: Coefficient of Friction = 0.5 with Tire (can be improved with surface texturing) Abutment Backfill: Prefer light weight material Color: Basic color is Graphite but can be produced in Gray, Beige, etc.

Fire Retardant Testing

Bridge Applications

Fort Leonard Wood, MO 1998 W = 26 ft; L = 24 ft Max Load = 25,000 lbs. 14

Wharton State Forest, NJ * Length - 56 feet * Live Load - HS 20 5 large I-beams rest on piles 6 small I-beams lock into place perpendicular to the large I-beams The top surface of the large I-beams serves as decking along with tongue and groove decking laid down parallel to the large I-beams 2002 15

Fort Bragg, NC 2009 Load Bearing Capability M1 Abrams Tank on the Bridge 2009 16

Fort Bragg Construction Pile Cap Installation Driving RSPC piles 17

World’s First Railroad Bridges Fort Eustis, Virginia 2010 Bridge No. 3 Bridge No. 7

World’s First Railroad Bridges Fort Eustis, Virginia Bridges No. 3 and No. 7 Live Load: Cooper E60 and 260 Kip alternate loading with 20% impact Deflection: L/600 Length of Piles: about 45 feet Capacity of piles: 17 – 20 tons in end bearing per Pile Abutments: Existing timber abutments retained RSPC Elements: Railroad ties, curbs, girders, shear blocks, pier caps, piles and transverse connectors

Fort Eustis, VA Typical Section

Fort Eustis Construction Splicing Driving RSPC Piles Pile Cap Installation

Fort Eustis Construction Transportation Storage Installation

Fort Eustis, VA Competed Bridge No. 3

Fort Eustis, VA Completed Bridge No. 7

Live Load Testing 25

Fort Eustis, VA Deflections Bridge No. 3 Bridge No. 7 Estimated Deflection = 0.25” Measured Deflection = 0.21” Bridge No. 3 Estimated Deflection = 0.32” Measured Deflection = 0.29” Bridge No. 7

Scotland Highway Bridges 2011

Scotland Highway Bridges

Scotland Highway Bridges

Scotland Highway Bridges

Maine Highway Bridge 2011

Maine Highway Bridge Before - 3 ft Culvert After - 13 ft Bridge

Maine Highway Bridge Abutment Backfilling Piles and Pier Cap

Exiting Bridge-Deteriorated Superstructure Ohio Highway Bridge Exiting Bridge-Deteriorated Superstructure

Ohio Highway Bridge New Bridge-Plan View

Ohio Highway Bridge New Bridge - Elevation

Ohio Highway Bridge Typical Section

Ohio Highway Bridge Pile Driving

Ohio Highway Bridge Beam Installation

Ohio Highway Bridge Deck Installation

Ohio Highway Bridge Opened in December 2012

Other Applications

Railroad Ties and Switch Set

Retaining Walls

Sound Walls

More Applications Marinas Fenders Jetties and Piers Platforms and Boardwalks Temporary Reusable Bridges Culverts

Acknowledgement Producer: Axion International, Inc. Designer: Parsons Brinckerhoff Inventor: Rutgers University

Conclusions Green, Sustainable and Durable Environmentally Beneficial Vast Areas of Application Accelerated Construction Minimal Maintenance Cost Competitive 48

Questions?