bridges

1Prefabricated Bridge Prefabricated Bridge Elements and SystemsElements and Systemsin Europe and Japanin Europe and Japan

2004 FHWA/AASHTO 2004 FHWA/AASHTO International Technology ScanInternational Technology Scan

Harry Capers, P.E., Harry Capers, P.E., New Jersey Department of New Jersey Department of

TransportationTransportationApril 15, 2005April 15, 2005

OverviewOverview Need for Prefabricated BridgesNeed for Prefabricated Bridges Mission and Scope of 2004 ScanMission and Scope of 2004 Scan Implementation RecommendationsImplementation Recommendations

Bridge Movement SystemsBridge Movement Systems Superstructure SystemsSuperstructure Systems Deck SystemsDeck Systems Substructure SystemsSubstructure Systems

Current and Future Scan ActivitiesCurrent and Future Scan Activities Initial DOT Implementation EffortsInitial DOT Implementation Efforts

2National Bridge InventoryNational Bridge Inventory

Over 150,000 bridges Over 150,000 bridges structurally deficient structurally deficient or functionally obsoleteor functionally obsolete

3,000 added annually3,000 added annually Increasing traffic Increasing traffic

volumes, weightsvolumes, weights Aging infrastructureAging infrastructure

Over 130,000 bridges Over 130,000 bridges recommended for recommended for replacement, ~$70B+replacement, ~$70B+

What is Driving the Change What is Driving the Change from Conventional from Conventional Construction?Construction? The infrastructure is aging needed

now are innovative solutions that canbe built quicker and that last longer

Goal: A minimum 75-yr service life Currently: Average bridge life is 42 yrs Average bridge deck life is 20-25 yrs

3Challenge of Bridge Challenge of Bridge Repair and ReplacementRepair and Replacement

Bridges must beBridges must berehabilitated or replacedrehabilitated or replacedwhile maintaining trafficwhile maintaining trafficflowflowFixing a car with Fixing a car with the engine runningthe engine running

WorkWork--zone Concerns: zone Concerns: congestion, traffic speed, congestion, traffic speed, time delays, accidentstime delays, accidents

Get in, Get out, Stay out!Get in, Get out, Stay out! Public prefers shortPublic prefers short--term term

shutdowns with longshutdowns with long--term resultsterm results Accelerated ConstructionAccelerated Construction

Reduces Construction Time &Reduces Construction Time &Traffic Control CostsTraffic Control Costs

Minimizes Traffic CongestionMinimizes Traffic Congestion Reduces Highway Worker Reduces Highway Worker & Motorist Exposure& Motorist Exposure

Enhances SafetyEnhances Safety Minimizes Impacts Minimizes Impacts Promotes Construction QualityPromotes Construction Quality

4Focus on Prefabricated Focus on Prefabricated Elements and SystemsElements and Systems

Scan MissionScan MissionTo investigate and document applications To investigate and document applications and experience of prefabricated bridges and experience of prefabricated bridges in Japan and select European countries, in Japan and select European countries, with emphasis on:with emphasis on:

Routine bridges with 20 ftRoutine bridges with 20 ft140 ft spans140 ft spans Innovative systemsInnovative systems Replacement as well as new highway Replacement as well as new highway

and railroad bridgesand railroad bridges Seismic considerations and Seismic considerations and

emergency workemergency work

5Scan TeamScan TeamFHWAFHWA Benjamin Tang, CoBenjamin Tang, Co--ChairChair Claude Napier, Jr., VAClaude Napier, Jr., VA Barry Brecto, WABarry Brecto, WA

IndustryIndustry Shri Bhide, PCA, National Shri Bhide, PCA, National

Concrete Bridge Council Concrete Bridge Council Henry G. Russell, Henry G. Russell,

FacilitatorFacilitator Market Development Market Development

Alliance, FRP (Invited)Alliance, FRP (Invited) National Steel Bridge National Steel Bridge

Alliance (Invited)Alliance (Invited)

State DOTState DOTss Mary Lou Ralls, CoMary Lou Ralls, Co--Chair, TXChair, TX Harry Capers, NJHarry Capers, NJ William Nickas, FLWilliam Nickas, FL Dan Dorgan, MNDan Dorgan, MN

National Association of National Association of County EngineersCounty Engineers

Eugene CalvertEugene Calvert

AcademiaAcademia Eric Matsumoto, California Eric Matsumoto, California

State University, SacramentoState University, Sacramento

Scan OrganizerScan Organizer John OJohn ONeill, ATINeill, ATI

Focus AreasFocus Areas Minimized traffic disruptionMinimized traffic disruption

Improved work zone safetyImproved work zone safety

Minimized environmental impactsMinimized environmental impacts

Improved constructibilityImproved constructibility

Improved product qualityImproved product quality

Lower lifeLower life--cycle costscycle costs

6ScopeScope Project Decision ProcessesProject Decision Processes

Design and Construction MethodsDesign and Construction Methods

Innovative and Conventional MaterialsInnovative and Conventional Materials

Cost Considerations Cost Considerations

Maintenance and InspectionMaintenance and Inspection

Scan ProcessScan Process

Interview owners, designers, Interview owners, designers, fabricators, and contractors fabricators, and contractors on project experienceson project experiences

Examine and evaluate Examine and evaluate prefabricated bridges via prefabricated bridges via field visitsfield visits

Evaluate documentationEvaluate documentation

Report findings & develop Report findings & develop National Implementation PlanNational Implementation Plan

7Scan CountriesScan Countries

1. Japan1. Japan

2. Netherlands2. Netherlands 3. Belgium3. Belgium

4. Germany4. Germany5. France5. France

HostsHostsJAPANJAPAN Japan Highway Public CorporationJapan Highway Public Corporation East Japan Railway CompanyEast Japan Railway Company Mitsubishi Heavy IndustriesMitsubishi Heavy Industries Sumitomo Mitsui Construction CompanySumitomo Mitsui Construction Company Mitsui Engineering and Shipbuilding Mitsui Engineering and Shipbuilding

CompanyCompany Kajima CorporationKajima CorporationNETHERLANDS/BELGIUMNETHERLANDS/BELGIUM MammoetMammoet CorporationCorporation SarensSarens

8HostsHostsGERMANYGERMANY Bavarian Construction Ministry, MunichBavarian Construction Ministry, Munich A3 A3 AnschlusstelleAnschlusstelle, Frankfurt, Frankfurt German Federal HighwayGerman Federal Highway Research Institute (Research Institute (BAStBASt), Cologne), Cologne

FRANCEFRANCE SNCF (French National Railway Authority)SNCF (French National Railway Authority) SETRA (Tech. Dept. for Public Works & SETRA (Tech. Dept. for Public Works & TranspTransp.).) LCPC (Central Laboratory for Public Works)LCPC (Central Laboratory for Public Works) CERIB (CERIB (TechicalTechical CtrCtr of Concrete Industry)of Concrete Industry) CETE (Technical Studies CETE (Technical Studies CtrCtr for Public Works)for Public Works) CPCBTP (Producer)CPCBTP (Producer) Lafarge CementLafarge Cement

HostsHosts

9Implementation Implementation RecommendationsRecommendations


Bridge Movement Bridge Movement SystemsSystems

SelfSelf--Propelled Modular Transporters Propelled Modular Transporters ((SPMTsSPMTs))

Other Bridge Installation SystemsOther Bridge Installation Systems Horizontal SkiddingHorizontal Skidding Incremental LaunchingIncremental Launching Floating MethodsFloating Methods PivotingPivoting Vertical LiftingVertical Lifting

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SPMTsSPMTs

Construct bridge offConstruct bridge off--line line then move onthen move on--line in hoursline in hours

44--6 axle lines, 33 tons/axle6 axle lines, 33 tons/axle ComputerComputer--controlled by one controlled by one

operatoroperator Horizontal movement in any Horizontal movement in any

direction, ~8% grades useddirection, ~8% grades used Equal loads maintained on Equal loads maintained on

axles on irregular surfacesaxles on irregular surfaces

The NetherlandsThe NetherlandsMammoetMammoet

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BelgiumBelgiumSarensSarens

Two 154Two 154--ton RR ton RR Bridges, GermanyBridges, Germany

SPMTsSPMTs

36003600--ton, 390ton, 390--ft Superft Super--structure Moved in structure Moved in

2 hours, Netherlands2 hours, Netherlands

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SPMTsSPMTs

19001900--ton Bridge ton Bridge Movement, GermanyMovement, Germany

390390--ft, 900ft, 900--ton Twin ton Twin Steel Arch Bridges Steel Arch Bridges

Moved across CanalMoved across Canal

Lifting and Rolling of Complete 2200Lifting and Rolling of Complete 2200--ton ton RR Bridge 1309, RR Bridge 1309, NohantNohant le Pin, Normandyle Pin, Normandy

SPMTsSPMTs

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Horizontal SkiddingHorizontal Skidding

Skidding of Complete Skidding of Complete 36003600--ton Bridge Using ton Bridge Using

Strand Jacks, NormandyStrand Jacks, Normandy

7272--hour Skidding hour Skidding of 10,500of 10,500--ton ton

Bridge/Abutments Bridge/Abutments on Track, UKon Track, UK

Incremental LaunchingIncremental Launching

ArimatsuArimatsu Viaduct, Viaduct, Above Route 23, Above Route 23, Nagoya, JapanNagoya, Japan

Two 6Two 6--span, 2150span, 2150--ft, ft, 13,00013,000--ton bridgeston bridges

Each span launched Each span launched in 12in 12--hour windowhour window

56 synchronized 56 synchronized 550550--ton, 9ton, 9--in stroke in stroke jacks control jacks control movementmovement

Course correction at Course correction at each benteach bent

22--in gap maintainedin gap maintained

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FloatingFloating

Floating 950Floating 950--ton ton Box Culvert Underpass, Box Culvert Underpass,

2222--hour installation, hour installation, St. Pierre St. Pierre dudu VauvrayVauvray

PivotingPivoting

Pivoting 2700Pivoting 2700--ton 262ton 262--ft Superstructure ft Superstructure 45 Degrees Using Synchronized Jacks 45 Degrees Using Synchronized Jacks and Guide Pin, and Guide Pin, ViaducViaduc do do VentabrenVentabren

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LiftingLifting

Hydraulic Jacks Used to Lift Hydraulic Jacks Used to Lift 13001300--ton Bridge Segmentton Bridge Segment

Implementation Implementation RecommendationsRecommendations


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Superstructure SystemsSuperstructure Systems

PoutrePoutre DalleDalle SystemSystem

PartialPartial--Depth Concrete Decks Depth Concrete Decks Prefabricated on Steel/Concrete Prefabricated on Steel/Concrete Beams Beams

UU--Shaped Segments Shaped Segments with Transverse Ribswith Transverse Ribs

PoutrePoutre DalleDalle SystemSystem Eliminates formwork, proEliminates formwork, pro--

vides safe working surfacevides safe working surface Precast, pretensioned Precast, pretensioned

invertedinverted--tees sidetees side--byby--sideside Overlapping hooks and CIP Overlapping hooks and CIP

for continuityfor continuity L~20L~20--82 ft, L/H~2882 ft, L/H~28--30 SS30 SS Width~16 inWidth~16 in--80 in (28 ton)80 in (28 ton) Fast, versatile, simple, Fast, versatile, simple,

durable, economical, safedurable, economical, safe

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PartialPartial--Depth Precast Depth Precast Decks on Steel or Concrete Decks on Steel or Concrete BeamsBeams

Precast Deck on Precast Deck on PC/PS Beam, GermanyPC/PS Beam, Germany

Precast Deck on Steel Precast Deck on Steel Beam, GermanyBeam, Germany

UU--Shaped Segments Shaped Segments with Transverse Ribswith Transverse Ribs

Restrictions: weight, height, environmentRestrictions: weight, height, environment Limited space for casting & stock yardLimited space for casting & stock yard Segments Segments 33 tons & 33 tons & 52 ft wide, haul 52 ft wide, haul

from plants w/in 37 mifrom plants w/in 37 mi

Furukawa Furukawa ViaductViaduct

L=4800 ftL=4800 ft

SideSide--byby--side PC/PS side PC/PS Box Girders Box Girders

41 11241 112--148 ft spans148 ft spans

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Hauling and Erection Hauling and Erection

Hauling of SectionHauling of Section Placement of precast Placement of precast panels prior to CIP panels prior to CIP

deck pourdeck pour

FullFull--Scale simple span test (L=125 ft) Scale simple span test (L=125 ft) Tested for all construction stagesTested for all construction stages 33--D FEA also conductedD FEA also conducted

MockMock--upup TestTest

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New New TomeiTomei ExpresswayExpresswayNew New MeishinMeishin ExpresswayExpressway



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Deck SystemsDeck Systems

FullFull--Depth Prefabricated Depth Prefabricated Concrete DecksConcrete Decks

Deck Joint Closure DetailsDeck Joint Closure Details Hybrid SteelHybrid Steel--Concrete Concrete

Deck SystemsDeck Systems Multiple Level Corrosion Multiple Level Corrosion

Protection Systems Protection Systems

ReducesReduces construction construction timetime, , formworkformwork, CIP, CIP ProvidesProvides qualityquality, , workwork surface, surface, safetysafety Route 23 Nagoya, fRoute 23 Nagoya, fullull--width pretensioned panels width pretensioned panels

(6.6 ft x 10.6 in x 49.2 ft) placed on steel girders(6.6 ft x 10.6 in x 49.2 ft) placed on steel girders Studs welded to girder, pockets grouted, closureStuds welded to girder, pockets grouted, closure

FullFull--Depth Pretensioned Depth Pretensioned DecksDecks

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Connection DetailsConnection DetailsOverlapping loopsOverlapping loops Full anchorage Full anchorage

w/o splicingw/o splicing Minimizes CIPMinimizes CIP Rigid for handling Rigid for handling

& placement& placement

R/C vs. Pretensioned DecksR/C vs. Pretensioned Decks

CIP Slab

PS Slab

Pretensioning Pretensioning allows allows longlong--span panels, span panels, reducing girder lines, reducing girder lines, minimizes tensionminimizes tension

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Deck Joint Closure DetailsDeck Joint Closure Details Transverse & longitudinal Transverse & longitudinal

joints for continuityjoints for continuity EpoxyEpoxy--coated loop barscoated loop bars Continuous center loopContinuous center loop Bars threaded throughBars threaded through FiberFiber--reinforced reinforced

expansive concreteexpansive concrete Experimental testingExperimental testing Waterproof membrane & Waterproof membrane &

asphalt wearing surfaceasphalt wearing surface

Hybrid SteelHybrid Steel--ConcreteConcreteDeck SystemsDeck Systems

LightLight--weight stayweight stay--inin--place formwork with place formwork with transverse joists for fast erectiontransverse joists for fast erection

Transverse joists support formwork & rebarTransverse joists support formwork & rebar Shear studs and CIP pour produce Shear studs and CIP pour produce

composite deck systemcomposite deck system

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MultipleMultiple--Level Corrosion Level Corrosion Protection SystemsProtection Systems

Asphalt wearing surf.Asphalt wearing surf.Asphalt protective layerAsphalt protective layerBituminous fabric sheetBituminous fabric sheetEpoxyEpoxy--coating covercoating coverConcrete coverConcrete cover



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SPER SystemSPER SystemSSumitomo umitomo PPrecast form for resisting recast form for resisting

EEarthquakes and for arthquakes and for RRapid construction apid construction

Segmental Pier SystemSegmental Pier SystemFactoryFactory--manufactured manufactured staystay--inin--place precast place precast concrete panels concrete panels w/CIP concretew/CIP concrete

Panels serve as both Panels serve as both formwork & structural formwork & structural elements. elements.

SPERSPER--LP SystemLP System Piers up to ~40 ftPiers up to ~40 ft 50% less construction time (660 ft total ht):50% less construction time (660 ft total ht):

formwork and curing time savingsformwork and curing time savings

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FormworkFormwork

After Casting After Casting & Formwork Removal& Formwork Removal In StockIn Stock

Rebar FabricationRebar Fabrication

SPERSPER--LP FabricationLP Fabrication

Lifting SegmentLifting Segment

Placing SegmentPlacing Segment

SPERSPER--LP LP Construction SequenceConstruction Sequence

Completed PiersCompleted Piers

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Hollow sectionHollow section Two C sections w/ lateral rebarTwo C sections w/ lateral rebar Lateral rebar coupled in fieldLateral rebar coupled in field Ties anchored w/ UTies anchored w/ U--barsbars

SPERSPER--HPHP SystemSystem Piers up to ~164 ftPiers up to ~164 ft 1/3 less in construction time (328 ft total ht):1/3 less in construction time (328 ft total ht):

formwork & lateral rebar installationformwork & lateral rebar installationHigh Strength Ti

LongitudinalPanel Re

Dowe

Casting BedCasting Bed FormworkFormwork

Casting ConcreteCasting Concrete CuringCuring StockStock

Rebar InstallationRebar Installation

SPERSPER--HP FabricationHP Fabrication

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SPERSPER--HP TransportationHP Transportation

Arrival at SiteArrival at Site

Leaving PlantLeaving Plant

ScaffoldingScaffolding Rebar InstallationRebar Installation

Coupling of Long. BarsCoupling of Long. Bars Coupled BarsCoupled Bars

Construction SequenceConstruction Sequence

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Construction SequenceConstruction SequencePrePre--Assembling FormsAssembling Forms Erecting Outer Form Erecting Outer Form

Applying Epoxy JointApplying Epoxy Joint

Construction SequenceConstruction SequenceForms Between SectionsForms Between Sections

Casting Between PanelsCasting Between Panels Completed PiersCompleted Piers

Intermediate HS Tie barsIntermediate HS Tie bars

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Current and Future Current and Future ActivitiesActivities

Disseminate Final ReportDisseminate Final Report Scan Technology Implementation PlanScan Technology Implementation Plan Implementation through Federal Implementation through Federal

Funding Programs, etc.Funding Programs, etc. Innovative Bridge Research and Innovative Bridge Research and

Deployment (IBRD)Deployment (IBRD) Highways for LIFEHighways for LIFE Federal BridgeFederal Bridge

STIPSTIP Identified 10 technologies in four Identified 10 technologies in four

categories for implementation in U.S. categories for implementation in U.S. STIP includes:STIP includes:

BackgroundBackground Implementation StrategyImplementation Strategy Scan Team LeadsScan Team Leads DeliverablesDeliverables TimeframeTimeframe Funds RequiredFunds Required

$85K Request for Development and $85K Request for Development and DisseminationDissemination

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STIP EffortsSTIP Efforts Disseminate technology via meetings, Disseminate technology via meetings,

workshops, articles, and websiteworkshops, articles, and website Solicit Pilot ProjectsSolicit Pilot Projects Obtain further informationObtain further informationdesign basis, design basis,

drawings, specifications, photosdrawings, specifications, photosfrom hostsfrom hosts Prepare Project Planning Guide and Draft Prepare Project Planning Guide and Draft

Specifications for use of Specifications for use of SPMTsSPMTs Translate documents, conduct lit searchTranslate documents, conduct lit search Recommend research Recommend research Coordinate with NCHRP and other Coordinate with NCHRP and other

organizationsorganizations

Initial DOT EffortsInitial DOT Efforts MNDOTMNDOTPoutrePoutre DalleDalle

PoutrePoutre DalleDalle--type deck slab for two bridges type deck slab for two bridges under development based on Scanunder development based on Scan

Interaction with Interaction with PrecastersPrecasters to develop feasible to develop feasible section without overhauling bedssection without overhauling beds

TxDOTTxDOTSPMTsSPMTs: Bridge Replacements : Bridge Replacements along Ialong I--35 corridor widening through 35 corridor widening through central Texas.central Texas.

FDOTFDOTSPMTsSPMTs: Rapid Repair of I: Rapid Repair of I--10 after 10 after Hurricane Ivan DamageHurricane Ivan Damage

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Hurricane Ivan IHurricane Ivan I--10 10 DamageDamage

East SideEast Side

West sideWest side

II--10 East Side Repair10 East Side Repair Phase 1: 24Phase 1: 24--day contractday contract Shifted 12 spans from East Shifted 12 spans from East

bound to open West boundbound to open West bound $250K/day incentive/$250K/day incentive/disincdisinc.. Contractor finished 7 days Contractor finished 7 days

earlyearly$1.75M bonus$1.75M bonus SPMTsSPMTs were instrumental to were instrumental to

moving 265moving 265--ton spanston spans

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Future DirectionsFuture DirectionsWidespread use of accelerated Widespread use of accelerated

construction (e.g., PBES) for bridges in construction (e.g., PBES) for bridges in urban areasurban areasIn each case, engineering the solution In each case, engineering the solution

to meet the unique constraints; i.e.,to meet the unique constraints; i.e., Reduced traffic disruptionReduced traffic disruption Improved workImproved work--zone safetyzone safety Reduced environmental impactReduced environmental impact Improved constructabilityImproved constructability Improved qualityImproved quality Lower lifeLower life--cycle costscycle costs

Future Directions, Future Directions, contcontd.d. More elements combined offMore elements combined off--sitesite More efficient, innovative prefabricated More efficient, innovative prefabricated

bridge systems using the enhanced bridge systems using the enhanced properties of high performance materialsproperties of high performance materials

More prefabricated substructuresMore prefabricated substructures More innovative methods of More innovative methods of

construction; e.g., use of selfconstruction; e.g., use of self--propelled propelled modular transporters (SPMTs), other modular transporters (SPMTs), other total bridge movements.total bridge movements.

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Future Directions, Future Directions, contcontd.d.

Increased focus on durability to extend Increased focus on durability to extend bridge service life to 75 yearsbridge service life to 75 years Rehabilitation of the existing Rehabilitation of the existing

infrastructure, with more public infrastructure, with more public involvement (CSS solutions)involvement (CSS solutions) More owner, industry, consultant, More owner, industry, consultant,

academia, public partnerships to find academia, public partnerships to find optimum solutionsoptimum solutions

A Suggested Role for You

Insist on consideration of innovativetechnologies to accelerate construction9 Be willing to specify the first use9 Select a large project or multiple projects

with repetitive sections for the first use9 Use contracting strategies that are

significant to the contractor9 Include cost trade-offs in project estimate9 Engage all stakeholders for their input,

from initial planning through construction

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Available ResourcesAvailable Resources

For PBES bridges and contact information For PBES bridges and contact information http://http://www.fhwa.dot.govwww.fhwa.dot.gov/bridge/prefab/ /bridge/prefab/

For Accelerated Construction Technology Transfer For Accelerated Construction Technology Transfer (ACTT) Workshop information (ACTT) Workshop information http://http://www.fhwa.dot.govwww.fhwa.dot.gov/construction/accelerate/construction/accelerated/ d/

FHWA technical workshops on innovative FHWA technical workshops on innovative techniquestechniques

Mark your calendars!

FHWA National Prefabricated Bridge Elements & Systems Workshop

December 12-14, 2005San Diego, California

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The future is here!:

Looking for a few champions

Thank You

SPMTSuperstructures & Decks

Substructures

bridges

Documents