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Dan Richards, Ph.D., P.E. President & CEO
T-8 AASHTO Technical Subcommittee for Movable Bridges
July 9, 2012 Austin, Texas
ZellComp® Composite Deck Systems
Morrison Bridge, Portland, OR
ZellComp’s Previous Experience in Portland, OR Partial Deck Replacement – Broadway - 2010
4 Lanes of Traffic; ADT = 30K; November 2011 July 9, 2012 T-8 Committee
Double Bascule Bridge ADT = 50,000 Built in 1958
Installation of the ZellComp® Composite Deck on the Morrison Bridge, Portland, OR
Morrison Bridge: Open Steel Grating – 6 Lanes
July 9, 2012
County’s Reason for Solid Decking - Traction T-8 Committee
ZellComp Composite Deck Design
Bottom Sections Pultruded
Prefabricated & Pre-Engineered Composite Decks 4.5”, 5”, 6.5” and 7” in Production
Top Sheet Pultruded
Pultrusion Process
Resin
Basic Steps in Pultrusion
Heated Die
Cured
Profile
T-8 Committee July 9, 2012
Morrison Bridge – Portland, OR
July 9, 2012
West Leaf Opened – July 2011 T-8 Committee
Installation of the ZellComp Composite Deck System on the Morrison Bridge
July 9, 2012
4 Quads – Staged Construction 1&2 / 3&4 T-8 Committee
4 1 2
3
Morrison Bascule Bridge – Portland, OR
-Started July 2011 -Staged Construction
T-8 Committee July 9, 2012
Bottom Sections Easy to Install
July 9, 2012
South Side (Quads 1 & 2) 42’ 9” Long; ~ 1,200 Lbs T-8 Committee
Bottom Sections on Steel Stringers
July 9, 2012
Connections: Neoprene used with Structural Bolts T-8 Committee
Installation of Bottom Sections
Structural Bolts (TC) with Neoprene – Tested by Multnomah County / Oregon DOT
T-8 Committee July 9, 2012
Field Adjustment: Easy with the ZellComp Deck
July 9, 2012 Toe and Heel ~ 3” Off at Steel Structures
T-8 Committee
Old Bridges Require Adjustments on Site
July 9, 2012
Last Bottom Section; Cut to Exact Fit at Heel T-8 Committee
Installation Advantages of the ZellComp Deck
July 9, 2012 T-8 Committee
Contractor Driving on Deck – Crane Not Needed
July 9, 2012 T-8 Committee
Contractor had Weight Balance Requirements
Installation Advantages of the ZellComp Deck
Installation of the Guardrails Attached to Deck
July 9, 2012 Contractor Used Old Rails as a Template
T-8 Committee
Installation of the Guardrail Post Pads
July 9, 2012
Reinforcement of the Local Deck Area for Posts T-8 Committee
Installation of the Top Sheets
July 9, 2012
Light Weight Composites – Accelerates Installation T-8 Committee
ZellComp’s Proprietary Drill Machines
July 9, 2012
3rd Generation Fastener System Installation T-8 Committee
Installation of the Top Sheets
July 9, 2012
Rain, Rain … let it Rain - Weather No Effect T-8 Committee
Sand Blast Top Sheets for WS
July 9, 2012
Sand Blasting on Site More to Clean the Surface T-8 Committee
Wear Surface Installation
July 9, 2012
Wet the Deck Surface with Primer/Adhesive T-8 Committee
Wear Surface Installation
July 9, 2012
Applying the Aggregate for the Polymer Concrete WS
T-8 Committee
Solid Surface vs Open Steel Grating
July 9, 2012
East Leaf Opened – November 2011 T-8 Committee
North Lanes Installation – January 2012
July 9, 2012 Northern 2 Quads Installation went Faster
T-8 Committee
Morrison Bridge – 3-8-12
July 9, 2012 T-8 Committee
Raised East Leaf – March 2012
July 9, 2012 T-8 Committee
Morrison Bridge
July 9, 2012
Opened to Traffic on March 24, 2012 T-8 Committee
Tangier Island, VA
Bradford, VT
Belle Glade, FL
Tippecanoe Co., IN
State College, PA
Broadway Bridge Portland, OR
Redstone Arsenal, AL
Morrison Bridge, Portland, OR
Thanks to the AASHTO T-8 Movable Bridge Committee ZellComp has ADT ~ 105,000 with 8 Installations
