H. Stewart Kline & Associates is now VS Engineering
Wednesday, November 14, 2018

153 FIBER REINFORCED POLYMER BRIDGE

    The project involved the removal of an existing non-composite portland cement concrete deck on steel beams and replacement with a new fiber reinforced polymer concrete deck providing a wider, lighter, corrosion resistant deck.
    After cleaning and repositioning the beams and modifying the mudwalls, a 28’-6” wide fiber reinforced polymer (FRP) deck, 7” in thickness, was set on the beams using welded stud and grouted haunches. The deck was set on a 2% cross slope, employing a bolted centerline joint. An expansion joint sealing system was installed at each end, where the deck meets the modified mudwall that accommodates the new joint. A polymer concrete wearing surface, ¾” in thickness, was field-applied to the completed deck.

    The existing steel beam superstructure was cleaned, coated, and reused. The five beams were re-positioned from the existing 5’-10” spacing to a 6’-3” spacing to limit the overhang length at the copings. The bearings were cleaned and painted before being re-installed in their new positions.  Studs were welded along the top flange of each beam for fastening to the deck elements, and grout haunches were installed on the top flanges in order to accommodate the deck cross slope and to make up for variations in the profiles of the beams, thereby ensuring secure fastening at all connections.

                                     Journal & Courier Article                               TV 18 Story


ROAD CLOSED

ROAD CLOSED

DECK CUT

DECK CUT

DECK LIFTED OFF

DECK LIFTED OFF

DIAPHRAGMS REMOVED

DIAPHRAGMS REMOVED

BEAMS PULLED

BEAMS PULLED

BEAMS BLOCKED FOR CLEANING AND PAINTING

BEAMS BLOCKED FOR CLEANING AND PAINTING

BEAMS TENTED FOR CLEANING

BEAMS TENTED FOR CLEANING

PRIME COAT APPLIED

PRIME COAT APPLIED

FINAL PAINT COAT APPLIED TO BEAMS

FINAL PAINT COAT APPLIED TO BEAMS

ROCKERS CLEANED AND PAINTED

ROCKERS CLEANED AND PAINTED

WINGS CUT TO ACCOMODATE WIDENED DECK

WINGS CUT TO ACCOMODATE WIDENED DECK

MUDWALLS EXTENDED

MUDWALLS EXTENDED

FLOWABLE FILL PLACED

FLOWABLE FILL PLACED

BEARINGS SET & BEAM INSTALLATION BEGINS

BEARINGS SET & BEAM INSTALLATION BEGINS

BEAMS RE-INSTALLED AT NEW SPACING

BEAMS RE-INSTALLED AT NEW SPACING

NEW DIAPHRAGMS CONNECTED

NEW DIAPHRAGMS CONNECTED

NEW LIGHT WEIGHT FIBER REINFORCED POLYMER PANELS

NEW LIGHT WEIGHT FIBER REINFORCED POLYMER PANELS

"FRP" PANEL INSTALLATION BEGINS

PANEL INSTALLATION CONTINUES

PANEL INSTALLATION CONTINUES

PANELS INSTALLED

PANELS INSTALLED

FORMS PLACED TO GROUT STUD LINES & RAIL ANCHORS

FORMS PLACED TO GROUT STUD LINES & RAIL ANCHORS

REINFORCEMENT AND STUDS AT RAIL ANCHOR

REINFORCEMENT AND STUDS AT RAIL ANCHOR

GROUT INSTALLED AT BRIDGE RAIL ANCHOR

GROUT INSTALLED AT BRIDGE RAIL ANCHOR

BRIDGE RAIL ANCHOR BOLTS AT COPING

BRIDGE RAIL ANCHOR BOLTS AT COPING

BRIDGE RAIL INSTALLED

BRIDGE RAIL INSTALLED

POLYMER DECK PLATES ARRIVE

POLYMER DECK PLATES ARRIVE

DECK PLATE INSTALLATION BEGINS

DECK PLATE INSTALLATION BEGINS

DECK PLATES ANCHORED

DECK PLATES ANCHORED

DECK PLATE INSTALLATION COMPLETED

DECK PLATE INSTALLATION COMPLETED

DECK END CAP INSTALLED

DECK END CAP INSTALLED

BACKER PLACED AT END OF DECK

BACKER PLACED AT END OF DECK

SEALANT INSTALLED

SEALANT INSTALLED

FIRST COAT OF POLYMER CONCRETE SURFACE APPLIED TO DECK

FIRST COAT OF POLYMER CONCRETE SURFACE APPLIED TO DECK

QUARTZ USED AS SURFACE AGGREGATE

QUARTZ USED AS SURFACE AGGREGATE

EXCESS AGGREGATE REMOVED

EXCESS AGGREGATE REMOVED

SECOND LAYER OF POLYMER CONCRETE SURFACE APPLIED

SECOND LAYER OF POLYMER CONCRETE SURFACE APPLIED

FINAL SURFACE TEXTURE

FINAL SURFACE TEXTURE

APPROACH IS MILLED

APPROACH IS MILLED

HMA SURFACE PLACED

HMA SURFACE PLACED

APPROACH GUARDRAIL INSTALLED

APPROACH GUARDRAIL INSTALLED

PROFILE STRAIGHT EDGE

PROFILE STRAIGHT EDGE

PROFILE GRINDING

PROFILE GRINDING

FINISHED APPROACH

FINISHED APPROACH

COMPLETED PROJECT

COMPLETED PROJECT