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

• 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

• $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 shortspan bridges.

• 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

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

 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

 Weight: 55pcf (Wood: 60pcf; Concrete: 150pcf; Steel: 490pcf)
 Specific Gravity: 0.85 – 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: 350 psi (Ult. = 1,500 psi)
 Coefficient of Thermal Expansion: 0.0000282 in/in/deg F

Typical Stress/Strain Curve

 Ultraviolet Degradation: Less than 0.003 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

(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.

W = 26 ft; L = 24 ft
Max Load = 25,000 lbs.
1998

* Length - 56 feet
* Live Load - HS 20
2002

Load Bearing Capability
2009
M1 Abrams Tank on the Bridge

Pile Cap Installation
Driving RSPC piles

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

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

Fort Eustis, VA
Typical Section

Fort Eustis Construction
Splicing
Driving RSPC Piles
Pile Cap Installation

Fort Eustis Construction
Storage
Transportation
Installation

Fort Eustis, VA
Competed Bridge No. 3

Fort Eustis, VA
Completed Bridge No. 7

Live Load Testing

Fort Eustis, VA
Deflections
Estimated Deflection = 0.25”
Measured Deflection = 0.21”
Bridge No. 3
Estimated Deflection = 0.32”
Measured Deflection = 0.29”
Bridge No. 7

Scotland Highway Bridges
2011

Scotland Highway Bridges

Scotland Highway Bridges

Scotland Highway Bridges

Maine Highway Bridge
2011

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

Maine Highway Bridge
Abutment Backfilling
Piles and Pier Cap

Ohio Highway Bridge
Exiting Bridge-Deteriorated Superstructure

Ohio Highway Bridge
New Bridge-Plan View

Ohio Highway Bridge
New Bridge - Elevation

Ohio Highway Bridge
Typical Section

Ohio Highway Bridge
Pile Driving

Ohio Highway Bridge
Beam Installation

Ohio Highway Bridge
Deck Installation

Ohio Highway Bridge
Opened in December 2012

 Marinas
 Fenders
 Jetties and Piers
 Platforms and Boardwalks
 Temporary Reusable Bridges
 Culverts

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

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