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

2. 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

3. Site Solutions for Bridge, Storm water, Drainage, Retaining Walls, Erosion Control, & Sanitary3

4. 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

5. Assemble and Slip line.

6. Back grout.

7. Structural Check HS-25 Live Load

8. Save $ million !!

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

10. 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.

11. 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.

12. 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)

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

14. 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

15. 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.

16. 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

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

18. 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.

19. 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.

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

21. 2-Flange Tunnel Liner Plate - Coatings
Galvanized Steel
Uncoated “Black” Steel
Aluminized Steel Type 2
Aluminum Alloy

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

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

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

25. Assembly of Tunnel Liner Plate Arch

26. Tunnel Liner Plate Arch 14-years after construction

27. MNDOT Project Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate

28. MNDOT Project Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate

29. MNDOT Project Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate

30. MNDOT Project Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate

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

32. MNDOT Project Nicollet Co TH 22, St Peter, MN Reline of twin 10’ X 10’ concrete pipe with Tunnel Liner Plate

33. . Two Harbors, MN 2 – 13’ span 2-Flange Tunnel Liner Plate State Aid Project , Bridge
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.

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

35. MNDOT State Aid , Duluth, MN 2nd St and 13th Avenue over Chester Creek - AL-T2 Flange Liner Plate Arch

36. 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

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

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

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

40. 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

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

42. Construction Plans

43. Traffic Continues on Highway During Construction which Eliminates Road Close Time

44. Photos during the construction process.

45. Project Under Construction Backfilling around new structure

46. Bridge Deck Left in Place Voids of bridge filled with grout

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

48. OHIO DOT Dayton Road - Clark County, Ohio CON/SPAN Reline of Concrete Bridge
Concrete channels cast and doweled into existing structure.

49. 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.

50. 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.

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

52. Express Foundations for ABC

53. Express Foundations loaded off the truck

54. Express Foundations ready for Aluminum Box Culvert

55. 22’9” Span X 5’4” Rise Aluminum Box Culvert
Filled with
CIP Concrete
EXPRESS Foundations

56. ALBC on Express Foundation ready for grout fill

57. Concrete is poured in void space of the Express Foundation

58. Finished Project – Culvert under Trunk Highway

59. One year after installation

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

61. Express Foundations Delivered on a Flat Bed Trailer

62. Express Foundations Lifted into Place

63. Connecting wing wall footing

64. Setting CON/SPAN Precast Structures

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

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

67. Express Foundations Set

68. Lifting Abutment Wall into Place

70. Abutment sitting on Express Foundation

71. Placing Abutment Wing Wall – Front Side Photo

72. Abutment wall – Rear Side Photo

73. Pouring Concrete in Express Void Space

74. Steel Truss Bridge – One week after Construction Start

75. Truss Bridge Cost – 55k, Express Foundation 59K

76. Your Project Partner
Providing assistance to the engineering community since 1904
Nationwide support with local representative to help you
Engineer Staff to help with drawings, plans, and specifications
Outstanding Free Design Tools on our Website for Bridge and Storm Water applications