Features Overview

Innovative Concrete -Whitley County Bridge

Bridge Deck Overlay using new experimental materials

This project represents a huge milestone for all levels of infrastructure maintenance,

especially in terms of sustainability and resilience in structure longevity. The

application of hydro-demolition was removed from the scope, as well as costly

surface grooving. Both processes are used by State and Federal Transportation and

place traditional costs out of reach for most local municipalities. This places our

local governments infrastructure in a perilous decision making process of allowing

for structural deficiency until the bridge meets qualification for replacement. The

Bridge Deck Overlay process can add crucial years to the life of the structure.

The true magic behind the success of such projects is to blend value engineering in

the preparation and construction methods along with revolutionary overlay mix

design. Traditional mix designs contain 658lb/cy cement with an additional 50lb/cy

of silica fume with a maximum W/C equal to 0.42. Problems encountered with this

mix involve decreases in workability, increased susceptibility to evaporation leading

to plastic shrinkage, and difficult curing techniques with expanded crew size.

The mix design on this project was designed specifically to counter the temperamental

characteristics of a typical bridge overlay mix. The cement content was reduced

from 658lb/cy to 580lb/cy. The costly, and inherently dangerous use of silica fume

(See OSHA Standards Relating to Silica) was eliminated. Instead, the mix was

designed with two revolutionary admixtures that promote internal curing (E5) and

SCM replacement (E5 Liquid Fly Ash). The use of the Liquid Fly Ash has shown to

be a cement replacement up to 15%. The nature of the Liquid Fly Ash, essentially

nano silica particles in a colloidal solution, promotes pozzolanic reaction along with

matrix density within the mix. Thus, reducing permeability, while promoting CSH

reaction. The mix also utilized the addition of fiber reinforcement to aid in shrinkage

control. The addition of E5 Internal Cure controlled evaporation and prevented

surface bleeding. The use of internal cure also saved cost in labor as no traditional

wet curing methods were used, as well as the elimination of curing compound.

In addition to cost savings, this concrete mix design also reduces carbon footprint.

The reduction in cement as well as the elimination of silica fume and the addition of

an SCM (E5 Liquid Fly Ash) that does not present itself thru carbon heavy production

(i.e. slag from blast furnace, traditional fly ash from coal furnace) makes for the

most environmentally friendly mix designs produced. This enhancement is furthered

in the use of E5 Internal Cure in preventing excessive water and material usage

associated with wet curing techniques.

Institutional and Cultural

Improving quality of life and providing multiple avenues for physical

activity are the hallmarks of any exceptional municipal parks and

recreation department facility. The $20 million, 135,000-sft sports hub

features six regulation-sized basketball courts that can be converted to

12 volleyball courts; two regulation-sized soccer fields; six indoor

batting cages; a quarter-mile, upper-level walking track; community

room; multipurpose room, and Union Lounge offering beverages to

the public.

The design team chose precast concrete panels for its durability and

aesthetic qualities. The ability to work with precast panels and the

level of finish of the precast was such that the facility achieved the

desired aesthetic. Nearly 135 concrete panels were installed to

provide a unique appearance both on the exterior and the interior. The

design team also chose concrete floors that are easily maintained. The

high tolerances on the flatness of the subfloor for the wood basketball

courts was specified and maintained for a successful flooring install.

General circulation areas utilized exposed concrete with a clear sealer

for a low maintenance solution.

The design team uniquely interspersed blue- and green-colored panels

with the precast concrete panels on the exterior to create a modern,

budget-driven community art piece on the facility’s exterior. This was

an affordable solution to transform the monumental scale of a large

precast building into a canvas for community artwork. The City

embraced this design approach and went one step further – using the

variations in color panels as inspiration to design a logo for the facility

and branded content.

Feature 3

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