Aluminum Bridge Decking 2014 AASHTO Bridge Conference

Transcription

1 Aluminum Bridge Decking 2014 AASHTO Bridge Conference

2 Leadership in Aluminum Bridge Decking AlumaBridge, LLC A company totally focused on the bridge market. Venture capital funding has allowed remaining development to be completed Commercial availability and sustainability have been established Improvements have made based on past applications Exclusive access to new manufacturing assets L. B. Foster Exclusive North American Distributor Ideal alternative for: Structurally deficient bridges Functionally obsolete bridges Moveable bridges Historic bridges

3 Solid Foundation & Well Positioned Successfully developed cutting-edge aluminum bridge technology 4 patents issued Friction stir welding introduced and automated Aluminum bridge decking tested and in service 4 decks built and installed; 70 installations in Europe 18 years of successful performance history in U.S. Florida DOT selects aluminum decking to replace steel open grid FDOT Research shared with bridge authorities across North America Testing program already underway Potential pilot bridges identified Growing interest in Canada Ministry of Transportation Quebec awards aluminum deck in October 2013 Installation planned for August 2014

4 Benefits of Solid Deck Aluminum Panels Lightweight structural aluminum to reduce dead-load Prefabricated for accelerated bridge construction Minimizes traffic interruptions and need for expensive traffic control 100-yr. bridge life potential Lower lifecycle costs Advantages over existing deck alternatives Corrosion resistant with minimal maintenance no painting! Better skid resistance and less road surface noise compared to grid decks Capable of a 3.5 cantilever on each side of bridge to widen roadway Simple mechanical connections for fast installation and easy inspection Damaged deck panels can be quickly replaced

5 8 Deep Deck Profile Replaces Concrete on Steel Girders

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7 5 Deep Deck Profile Replaces Grid Decks (Movable Bridges)

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9 Aluminum Deck Features Weight: lbs./sq. ft. (depending upon deck depth and wearing surface) Structural Efficiency Composite or non-composite behavior with steel beams Similar to monolithic concrete deck 90% as strong transversely as longitudinally HL-93 loading capable Durability & service life Designed for infinite fatigue life using AASHTO Specifications Polymer concrete (2-part epoxy/aggregate) performs well on highways Impacts from pneumatic tires not a concern Meets LRFD code Corrosion, chemical, UV, and wear resistant

10 Aluminum Deck Features Maintenance Requirements No painted or corroded surfaces Wearing surface can be removed and applied in field (sustainable) Constructability Meets goals for Accelerated Bridge Construction (ABC) Rapid deployment of lightweight panels Simple mechanical (friction) connections Adaptability Decks in service with girder spacing up to 9 Potential to reuse beams Addresses functionally obsolete bridges (too narrow) with 3.5 cantilever

11 Aluminum Deck Features Wearing Surface 2-part epoxy wearing surface Variety of aggregates and colors for wearing surface Functionality and Safety Noise reduction compared to steel open grid Improved skid resistance (0.8 to 0.9 friction coefficient)

12 Aluminum Deck Features Sustainability Damaged deck panels can be quickly and easily replaced Wearing surface can be removed and applied in field (sustainable) Experience and Performance Decades of aluminum bridge applications and evolution 100-year deck technology may have been deployed 18 years ago Pricing: $150/sq. ft. *(Assumes cost of aluminum at $1.00/lb. metal cost is a pass through)

13 New 8 Deck Extrusion Profiles

14 St. Ambroise River Bridge Shop Drawings Quebec, Canada

15 Field Connection of Panels 5 Deck Profile for Moveable Bridges

16 Supply Chain Extrusion Trials February 6, 2014 New deck profiles optimized for friction stir welding with.850 top flange Extrusion trials confirm 32 maximum length for 5 deck Extrusion trials confirm 33 maximum length for 8 deck

17 5 Deck - Base Extrusion Profile 5 Deck - End Extrusion Profile New 6063-T6 alloy chemical composition offers improved ductility and fatigue resistance End extrusion offers structural panel closure and width adjustability End extrusion legs can be trimmed back for 4.5 of panel width variance Three FSW tests for quality assurance Macro Analysis: Cut, polish, and analyze weld core during pre-production trials Tensile Tests at start and stop of weld seams Force Analysis: Compares forces of welder for acceptable welds in trials to production welds

18 WELDING ALUMINUM ORTHOTROPIC DECK Corbin Bridge Huntingdon, PA

19 Case Study Aluminum deck installed on the Corbin Bridge in Huntingdon, PA A historic bridge, so reconstruction was not an option Bridge posted for 7 tons before rehab Over 80,000 pounds of dead-load removed Load rated for 24 tons after rehab Performing well after 18 years of service Before After

20 U.S. Route 58 Virginia - Bridge was functionally obsolete - Bridge was widened using existing substructure

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24 Sandisfield, MA Bridge Completion & Shipment

25 Sandisfield, MA Bridge Lifting & Positioning: 15 minutes

26 Sandisfield, MA Bridge Placement to Bearings: 15 minutes From crane to bearings in 30 minutes!

27 Manufacturing Supply Chain in Place AlumaBridge has entered long-term exclusive manufacturing supply agreement Extrusion production from world s largest aluminum profiler New fabrication equipment for precision-welded deck panels Automation platform designed to meet market demand $4M Friction Stir Welding Machine

28 Aluminum-to-Steel with Zinc Coating Electrical Potential Metal or alloy Potential (mv) silver -130 titanium -150 nickel -200 bronze -360 copper -360 steel -610 cadmium -700 aluminum (6063) -740 zinc magnesium Because the difference between aluminum s potential (-740) and steel s potential (-610) exceeds 100 mv, galvanic corrosion is possible when they are in contact. Since aluminum s potential is less than steel s, aluminum can be corroded by this contact, while the steel is protected.

29 Corrosion Resistance 53-Year Aluminum-to-Steel Connection

30 Movable Bridge Applications Improved safety Better skid resistance No see through decks No car steering influences Quick installation Rehabilitation potential Reduced maintenance Enhanced longevity

31 FHWA & VTRC Sponsored Evaluations FHWA article written by Bill Wright and published in Public Roads Magazine,1997 Spring Edition. Article written by the Virginia Transportation Research Council regarding tests performed on Little Buffalo Creek Bridge. Article on aluminum bridge deck built by Reynolds Metals Co. and written by VTRC.

32 FDOT Study Replacement of Steel Open Grid

33 Lightweight Bridge Deck RFP Template Performance-based bid template No mention of aluminum Similar templates for Roadway Asset Management already in use Works well with design/build projects Avoids sole-source concerns with proprietary/patented products Delivers best value for bridge owners (technical proposal + price) Bid model reviewed and supported by FHWA

34 Contact Info Mike Riley Marketing Manager Construction Products Bridge Group 415 Holiday Drive Pittsburgh, PA (412) Phone (724) Cell