BASCULE BRIDGE LIGHTWEIGHT SOLID DECK RETROFIT RESEARCH PROJECT DECK ALTERNATIVE SCREENING REPORT FINAL FPID 419497‐1‐B2‐01 Prepared for: Florida Department of Transportation Structures Design Office Prepared by: URS Corporation, Inc. 7650 West Courtney Campbell Causeway, Suite 700 Tampa, Florida 33607 May 14, 2012 TABLE OF CONTENTS 1.0 INTRODUCTION AND EXECUTIVE SUMMARY ................................................................................... 1 1.1 PROJECT NEED ............................................................................................................................... 1 1.2 DECK SELECTION FACTORS ............................................................................................................ 2 1.2.1 General .................................................................................................................................. 2 1.2.2 Weight Considerations .......................................................................................................... 3 1.2.3 Deck Thickness Considerations ............................................................................................. 5 1.2.4 Deck Attachment Considerations ......................................................................................... 6 1.2.5 Bascule Leaf Framing System Considerations ....................................................................... 6 1.2.6 Constructability Considerations ............................................................................................ 7 1.2.7 Design Considerations ........................................................................................................... 8 1.2.8 Financial and Technical Support Considerations .................................................................. 8 1.2.9 Maintenance and Durability Considerations ........................................................................ 8 1.3 LIGHTWEIGHT SOLID DECK SYSTEM EVALUATION ........................................................................ 9 1.3.1 Evaluated Deck Systems ........................................................................................................ 9 1.3.2 Evaluation Process ................................................................................................................ 9 1.3.3 Evaluation Findings ............................................................................................................. 11 2.0 OVERVIEW OF EVALUATED LIGHTWEIGHT SOLID DECK SYSTEMS ................................................. 18 2.1 SANDWICH PLATE SYSTEM (SPS) DECK ....................................................................................... 18 2.1.1 Description .......................................................................................................................... 18 2.1.2 Product Development and Corporate Information ............................................................ 20 2.1.3 Constructability ................................................................................................................... 20 2.1.4 Functionality and Safety...................................................................................................... 22 2.1.5 Design and Analysis ............................................................................................................. 23 2.1.6 Durability and Service Life ................................................................................................... 27 2.1.7 Maintenance ....................................................................................................................... 29 2.1.8 Research .............................................................................................................................. 30 2.1.9 Recent Bridge Installations ................................................................................................. 30 2.1.10 Florida Bascule Bridge Specific Solution ............................................................................. 33 2.1.11 Costs .................................................................................................................................... 37 FPID 419497‐1‐B2‐01 Bascule Bridge Lightweight Solid Deck Retrofit Research May 14, 2013 i FINAL Deck Alternative Screening Report 2.1.12 References .......................................................................................................................... 38 2.2 ALUMINUM ORTHOTROPIC DECK ............................................................................................... 40 2.2.1 Description .......................................................................................................................... 40 2.2.2 Product Development and Corporate Information ............................................................ 41 2.2.3 Recent Bridge Installations ................................................................................................. 44 2.2.4 Florida Bascule Bridge Specific Solution ............................................................................. 46 2.2.5 Functionality and Safety...................................................................................................... 51 2.2.6 Durability and Service Life ................................................................................................... 51 2.2.7 Design and Analysis ............................................................................................................. 55 2.2.8 Constructability ................................................................................................................... 55 2.2.9 Costs .................................................................................................................................... 56 2.2.10 References .......................................................................................................................... 58 2.3. FIBERGLASS REINFORCED POLYMER (FRP) COMPOSITE DECK ................................................... 59 2.3.1 Description .......................................................................................................................... 59 2.3.2 Product Development and Corporate Information ............................................................ 60 2.3.3 Recent Bridge Installations ................................................................................................. 61 2.3.4 Design and Analysis ............................................................................................................. 66 2.3.5 Functionality and Safety...................................................................................................... 69 2.3.6 Durability and Service Life ................................................................................................... 70 2.3.7 Florida Bascule Bridge Specific Solution ............................................................................. 77 2.3.8 Constructability ................................................................................................................... 80 2.3.9 Costs .................................................................................................................................... 81 2.3.10 References .......................................................................................................................... 83 2.4 ULTRA‐HIGH PERFORMANCE CONCRETE (UHPC) DECK .............................................................. 85 2.4.1 Description .......................................................................................................................... 85 2.4.2 Product Development and Corporate Information ............................................................ 88 2.4.3 Recent Bridge Installations ................................................................................................. 88 2.4.4 Florida Bascule Bridge Specific Solution ............................................................................. 89 2.4.5 Functionality and Safety...................................................................................................... 91 2.4.6 Durability and Service Life ................................................................................................... 92 2.4.7 Maintenance ....................................................................................................................... 93 2.4.8 Design .................................................................................................................................. 94 FPID 419497‐1‐B2‐01 Bascule Bridge Lightweight Solid Deck Retrofit Research May 14, 2013 ii FINAL Deck Alternative Screening Report 2.4.9 Research .............................................................................................................................. 94 2.4.10 Constructability ................................................................................................................... 94 2.4.11 Costs .................................................................................................................................... 95 2.4.12 References ........................................................................................................................ 101 3.0 WEARING SURFACE EVALUATION ................................................................................................. 102 3.1 INTRODUCTION ........................................................................................................................