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

2. 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

3. 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.

4. 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

5. From Wasteful to Useful

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

7. 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

8. Thermoplastic Properties
Weight: 55pcf (Wood: 60pcf; Concrete: 150pcf; Steel: 490pcf)
Specific Gravity: – 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: psi (Ult. = 1,500 psi)
Coefficient of Thermal Expansion: in/in/deg F

9. Typical Stress/Strain Curve

10. Design Considerations
Ultraviolet Degradation: Less than 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

11. 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.

12. Fire Retardant Testing

13. Bridge Applications

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

15. 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

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

17. Fort Bragg Construction
Pile Cap Installation
Driving RSPC piles 17

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

19. 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

20. Fort Eustis, VA
Typical Section

21. Fort Eustis Construction
Splicing
Driving RSPC Piles
Pile Cap Installation

22. Fort Eustis Construction
Transportation
Storage
Installation

23. Fort Eustis, VA
Competed Bridge No. 3

24. Fort Eustis, VA
Completed Bridge No. 7

25. Live Load Testing 25

26. 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

27. Scotland Highway Bridges
2011

28. Scotland Highway Bridges

29. Scotland Highway Bridges

30. Scotland Highway Bridges

31. Maine Highway Bridge
2011

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

33. Maine Highway Bridge
Abutment Backfilling
Piles and Pier Cap

34. Exiting Bridge-Deteriorated Superstructure
Ohio Highway Bridge
Exiting Bridge-Deteriorated Superstructure

35. Ohio Highway Bridge
New Bridge-Plan View

36. Ohio Highway Bridge
New Bridge - Elevation

37. Ohio Highway Bridge
Typical Section

38. Ohio Highway Bridge
Pile Driving

39. Ohio Highway Bridge
Beam Installation

40. Ohio Highway Bridge
Deck Installation

41. Ohio Highway Bridge
Opened in December 2012

42. Other Applications

43. Railroad Ties and Switch Set

44. Retaining Walls

45. Sound Walls

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

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

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

49. Questions?