1. M-25 over Harbor Beach Creek

2. 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

3. 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’.

4. “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

5. “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

6. 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 – 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

7. 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 – 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

8. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

9. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

10. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

11. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

12. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

13. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

14. M-25 over Harbor Beach Creek
Progress Clause says May 14 start to Aug 25 open to traffic.
13.3 mile detour – 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

15. 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 – 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

16. 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 – 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

17. 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 – 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

18. 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

19. 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

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

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

22. MDOT CFRP Deployment
NEFMAC Grid installation
Finished installation 22

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

24. MDOT CFRP Deployment Complete Pembroke Structure
Photos taken October 2011 24

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

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

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

28. 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

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

30. 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

31. 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

32. Thank you
Questions?