Merv Eriksson Project Leader. Sharon Kosmalski Project Assistant. July 2006

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1 James Scott Groenier Project Leader Merv Eriksson Project Leader Sharon Kosmalski Project Assistant USDA Forest Service Technology and Development Program Missoula, MT 7E72H69 FHWA Fiber-Reinforced Polymer Trail Bridges July 2006 This document was produced in cooperation with the Recreational Trails Program of the Federal Highway Administration, U.S. Department of Transportation. This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its contents or use thereof. The contents of this report reflect the views of the authors, who are responsible for the accuracy of the data presented herein. The contents do not necessarily reflect the official policy of the Department of Transportation. This report does not constitute a standard, specification, or regulation. The United States Government does not endorse products or manufacturers. Trade or manufacturer s names appear herein only because they are considered essential to the object of this document. The Forest Service, United States Department of Agriculture (USDA), has developed this information for the guidance of its employees, its contractors, and its cooperating Federal and State agencies, and is not responsible for the interpretation or use of this information by anyone except its own employees. The use of trade, firm, or corporation names in this document is for the information and convenience of the reader, and does not constitute an endorsement by the Department of any product or service to the exclusion of others that may be suitable. The U.S. Department of Agriculture (USDA) prohibits discrimination in all its programs and activities on the basis of race, color, national origin, age, disability, and where applicable, sex, marital status, familial status, parental status, religion, sexual orientation, genetic information, political beliefs, reprisal, or because all or part of an individual s income is derived from any public assistance program. (Not all prohibited bases apply to all programs.) Persons with disabilities who require alternative means for communication of program information (Braille, large print, audiotape, etc.) should contact USDA s TARGET Center at (202) (voice and TDD). To file a complaint of discrimination, write to USDA, Director, Office of Civil Rights, 1400 Independence Avenue, S.W., Washington, D.C , or call (800) (voice) or (202) (TDD). USDA is an equal opportunity provider and employer. i

2 Acknowledgments For reviewing the manuscript: Gary Jakovich, U.S. Department of Transportation Federal Highway Administration Eric Johansen, E.T. Techtonics, Inc. Cam Lockwood, Trails Unlimited Kathie Snodgrass, Missoula Technology and Development Center Brian Vachowski, Missoula Technology and Development Center Jim Wacker, Forest Products Laboratory Dan Witcher, Strongwell For assistance with bridge inspections: David E. Michael, Tahoe National Forest Randall K. Nielsen, Wallowa-Whitman National Forest Marcia J. Rose-Ritchie, Medicine Bow-Routt National Forests Kathryn Van Hecke, Pacific Northwest Region For photos used in this report: Trails Unlimited, E.T. Techtonics, Inc., and Strongwell ii

3 Introduction 1 Background on FRP Trail Bridges 3 Composites at a Glance 3 Pultrusion 4 Advantages of FRP Materials 4 Disadvantages of FRP Materials 5 Cost 5 Planning, Ordering, and Installing FRP Trail Bridges 6 Planning 6 Types of Composite Bridges 6 Delivery Methods 7 Ordering an FRP Bridge 8 Transportation, Handling, and Storage 9 Construction and Installation 9 Safety and Tools 15 Design of FRP Bridges 16 Design Specifications for FRP Pedestrian Bridges 16 Design Concerns 16 Other Concerns 17 Inspecting and Maintaining FRP Bridges 18 Visual Testing 18 Tap Testing 18 Thermal Testing 18 Acoustic Testing 19 Ultrasonic Testing 19 Radiography 19 Modal Analysis 19 Load Testing 19 Comparison of Inspection Methods 20 Qualifications for Inspectors 20 Visual Signs of Damage and Defects 20 Side Trusses 20 Deflection 21 Connections 21 Blistering 21 Voids and Delaminations 21 Discoloration 22 Wrinkling 22 iii

4 Fiber Exposure 22 Cracks 22 Scratches 23 Repair and Maintenance 23 Bridges Tested at the Forest Products Laboratory 24 Design Overview 24 Materials 24 Simulated Design Live Load Testing 25 Analysis of Test Data 26 Disassembly and Installation at Field Sites 27 Falls Creek Trail Bridge 27 Peavine Creek Trail Bridge 28 Reinspection 28 Case Studies and Failures 29 Transportation and Storage Problems 29 Construction Problems 29 Environmental Problems 31 FRP Trail Bridge Failures 32 Redwood National Park 32 Olympic National Park 33 Aquarium of the Americas 33 iv

5 Recommendations 34 Selection Considerations 34 Materials, Testing, Specifications, and Standardization 34 References 37 Appendix A Glossary 37 Appendix B Proposed Guide Specifications for the Design of FRP Pedestrian Bridges 51 Appendix C CSI Specifications for FRP Pedestrian Bridges 60 Appendix D Test Data for Bridges at the Forest Products Laboratory 65 Appendix E FRP Trail Bridges in the United States 70 Appendix F Web Sites 76 Appendix G FRP Suppliers, Designers, and Associations 75 Appendix H Design of the Falls Creek Trail Bridge 77 Appendix I Example Installation Instructions 92 v

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