Dave Whitmore (on the left) at TSP2 with Wayne Senick of Termarust Technologies

Author: Lorella Angelini, Angelini Consulting Services, LLC

Dave Whitmore is the President and Chief Innovation Officer for Vector Corrosion Technologies Ltd., a Canadian company based in Winnipeg, Manitoba, that operates in North America and worldwide.

Dave has an unmatched knowledge and experience related to bridge preservation. He started dealing with preservation issues early in his career that has spanned from contracting to manufacturing and consulting.

Dave is active in AASHTO, TSP2 and TRB. He also participates in industry organizations that focus on concrete repair and corrosion.

Can you illustrate the path that led you to become the President of Vector Corrosion Technologies?

It started in the 1960’s when my father and two partners established a construction business focusing on road and highway construction. The company then got into concrete restoration and became Vector Construction. Having been involved in the family business, I got an opportunity to be exposed to concrete repair early in my career thus gaining knowledge and experience in the concrete restoration industry.

After graduating with an engineering degree from the University of Manitoba and an MBA from the Ivey School of Business, I went to work for Vector Construction. I established Vector Corrosion Technologies in the 1990’s, focusing on the product and technology side of the concrete repair business.

What about your commitment to the industry? I know that you are active with several Committees related to bridge preservation, concrete restoration, and steel corrosion.

I enjoy our industry and the opportunity to participate in a number of industry organizations.

With regard to bridge preservation, I am part of the TRB Bridge Preservation Committee. (Ed Note: see Linkage section). This is a very interesting and useful Committee that promotes bridge preservation at quite a high level within DOTs. I did a presentation for that Committee last year. (Ed Note: see Linkage section). The year before I did a presentation for a session that was sponsored by the same Committee

I am a big supporter of TSP2. I especially support the annual Regional Meetings and the National Conference that takes place every four years. These gatherings are a great opportunity for industry and DOT representatives to come together, discuss and solve problems.

I am involved in other industry groups that are not specific to bridge preservation but share many of the same concerns. These are the American Concrete Institute (ACI), the International Concrete Repair Institute (ICRI), the National Association of Corrosion Engineers (NACE), the Post-Tensioning Institute (PTI) and the American Segmental Bridge Institute (ASBI). (Ed Note: see Linkage section). They are all really good organizations. I am on a number of Committees with these organizations concerning repair, corrosion, specifications and codes. Hopefully the activity of these Committees will help the industry to be more productive and effective in the future. On a personal level, I am happy that I get to meet and spend time with a lot of interesting people.

Vector Corrosion Technologies offers products and services to solve corrosion problems, as it is summarized by the tagline: “Innovative Solutions for Corrosion Problems”.  Can you introduce your company? Is bridge preservation a focus sector?

Helping owners extend the service life of their concrete structures is the mission of Vector Corrosion Technologies.

Bridge preservation is a key market segment for Vector. Both in North America and internationally, our focus is on structures that have durability challenges, such as marine structures and bridge decks that are exposed to de-icing salts.  These structures suffer the most from corrosion and can really benefit from pro-active bridge preservation activities.  (Ed Note: see Linkage section).

Can you speak of your core values as the leader of Vector Corrosion Technologies?

Persistence and honesty are my core values and I look for these values in everyone I work with. Striving for knowledge and continuing to learn every day is also important. At Vector, these values help us to address a lot of the problems we see out there.

Vector’s tag line, “We Save Structures”, is at the core of the company’s strategy for bridge preservation. Has Vector’s strategy evolved over time? If so, how?

There is no question that Vector has evolved over time. We started as a contractor and we are now involved in determining the cause of concrete deterioration problems and recommending appropriate repair solutions. We are engaged in the overall process, which helps make sure that our customers have positive results.

It may not be widely known but a lot of concrete repairs have not performed very well, or, at least, have not performed as intended over time. There have been a number of reports about this issue. I believe the major reason why many repairs have performed below expectations is that they have been simply cosmetic and have not addressed the underlying cause of concrete deterioration.

Vector focuses on the evaluation so that we can understand the underlying causes of deterioration and develop a durable, long-term repair strategy.

If I understand correctly, filling a concrete pothole is not enough. In order to have a successful repair, it is important to evaluate the root cause that generated that pothole.

Yes, it is easy to do what somebody asks you to do. Do you want me to patch this pothole?  Yes, I will patch the pothole. Do you want me to repair this crack? OK, I will repair the crack. But if I don’t address what caused the pothole or the crack, fixing the pothole or the crack will likely be temporary and in the long term will likely end up being a waste of time and money.

What are the most popular products and services that Vector currently offers for bridge preservation?

Our most popular products for bridge preservation are definitively the galvanic anodes that help prevent corrosion of reinforcing steel. These products are widely used since they are effective, measurable and very simple to install.

In terms of services, investigation and testing are critically important in order to determine cause and extent of corrosion problems. Providing these services was a very small part of our business twenty years ago. The evaluation business has increased significantly as people are becoming more aware that it is important to address the underlying cause of a problem and not just fix where they see visible damage.

Does Vector Corrosion Technologies offer these services directly to DOTs?

In some cases we provide evaluation services directly the DOTs. In many cases we work as a sub-consultant to a prime consultant that is under contract to the DOT.  We are not a structural engineering firm.  We support structural consultants with evaluation and testing services.

Has Vector recently released new products or new services for bridge preservation?

We have released three new products specifically for bridge preservation.

The first is in the area of galvanic anodes. We released a new line of galvanic anodes that are faster to install.  These anodes can be installed in approximately half the time required to install standard anodes. This saves time on site and money as a result of the reduced installation time. (Ed Note: see Linkage section).

The second product is a galvanic jacket specifically designed for marine structures. Very often the main issue with coastal or marine bridges is corrosion of the columns that support the superstructure. If you extend the service life of the columns then you can significantly extend the service life of the entire bridge. The new jacket provides improved corrosion protection for the columns from the water line up. Being modular, it is easy to install and can be modified in the field to suit different site conditions. (Ed Note: see Linkage section).

The third new product is designed to solve a specific and really important problem related to post-tensioned structures. Working together with Florida DOT, we developed a corrosion protection impregnation technique for post-tensioned bridge tendons. Like any other type of steel, post-tensioned tendons will corrode if they are not well protected. This can lead to tendon failures and eventually bridge closure. Vector’s new post-tension impregnation technique has been shown to reduce corrosion of the tendons by 95%, thus dramatically increasing DOTs’ confidence in the condition of their post-tension structures. (Ed Note: see Linkage section).

Could you point out a major challenge that Vector Corrosion Technologies is facing in promoting products and services for bridge preservation? If so, what is your advice on how to overcome this challenge?

Despite increasing awareness of the importance of bridge preservation, people still spend a lot of time and money on cosmetic repairs. As we discussed earlier, cosmetic repairs are temporary since they don’t usually address the underlying cause of the problem. As a result, owners end up spending more money than necessary for concrete repairs.

My advice is for DOTs to adopt performance specifications and performance requirements. Most DOT specifications are prescriptive and they are often written to the lowest common denominator.  This can only lead to low quality work.  On the other hand, if you hold the contractor responsible for the work that is performed, the contractor will take more care with the installation thus improving the overall performance of the work.

Could you further comment about prescriptive Vs performance-based specifications?

In my experience prescriptive specifications are not effective unless they are very detailed and there is a way of checking all of the steps that are specified.

As an example, there are many bridge deck overlay and repair specifications that state “clean the surface” or “provide a certain roughness of the substrate” but ultimately bond is what really counts. Having a performance specification that requires a minimum bond strength and provides a way to measure it, is more important than a series of prescriptive statements where no one is held responsible for the final outcome.

With regard to corrosion, there are some very important steps that must be taken. For example, it is important to clean the reinforcing steel to ensure there is good electrical contact between the anode and the steel. However, specifications should not only require “cleaning of the steel”, but they should also include performance requirements where the electrical connection is actually measured and confirmed.

LINKAGE

Vector Corrosion Technologies web site:
https://www.vector-corrosion.com/

TRB AHD37 – Standing Committee on Bridge Preservation Committee web site:
https://www.mytrb.org/OnlineDirectory/Committee/Details/4256
https://sites.google.com/site/trbbridgepreservationahd37/

Dave Whitmore 2017 TRB Power Point presentation:
https://www.vector-corrosion.com/presentations/TRB%202018%20Bridge%20Preservation.pptx

We Save Structures: Concrete Preservation & Restoration – Preservation is a Sustainable Practice video:
https://www.youtube.com/watch?v=Ef21EEVM-J0&t=9s

Concrete Preservation Alliance web site:
https://wesavestructures.info/

Galvashield XP Compact – Single Wire vs Two Wire Anode Installation video:
https://youtu.be/PUTVfiKp5nI

Galvashield Fusion T2 Anode for Concrete video
https://youtu.be/E4sa6TU8u1E

Galvashield Jacket Systems – Mitigating Corrosion to Extend the Life of Marine Piles PDF:
https://www.vector-corrosion.com/uploads/content/01Galvashield%20Jacket%20Systems%20Bro%20final%20lr.pdf

Post-Tech PTI Impregnation System – Corrosion Protection System for Bonded Post-Tension Tendons PDF:
https://www.vector-corrosion.com/uploads/content/PTI%20Broch%20Final%20Low%20Res.pdf

American Concrete Institute (ACI)
www.concrete.org

International Concrete Repair Institute (ICRI)
www.icri.org

National Association of Corrosion Engineers (NACE)
www.nace.org/home.aspx

Post-Tensioning Institute (PTI)
www.post-tensioning.org

American Segmental Bridge Institute (ASBI)
www.asbi-assoc.org/index.cfm

Raj Ailaney, chair of the FHWA BPETG

Author: Lorella Angelini, Angelini Consulting Services, LLC

Raj Ailaney is the chair of the Bridge Preservation Expert Task Group (BPETG) that gathers more than 20 people representing FHWA, TSP2 BPP, AASHTO, TRB, academia and industry. I contacted Raj to know more about the goals and the activity of this group that puts together such an unmatched depth of bridge preservation knowledge and expertise.

Could you introduce yourself? What is your education? What are the key points of your professional career?

I am a Senior Bridge Preservation Engineer with the Office of Bridges and Structures, Federal Highway Administration (FHWA) Headquarters in Washington, DC. In this position, I develop guidance and policies for preservation of bridges in support of FHWA’s performance-based program to maintain a state of good repair.

I’ve been with FHWA since 2003 and in my current position since early 2016. Prior to this position, I was an Acting Senior Advisor to the Associate Administrator of Office of Infrastructure. In that position, I provided support and guidance to the FHWA leadership on program and policy issues having national, regulatory, and legislative implications. Before joining FHWA, I was a Project Director with a Consulting Engineering firm in Northern Virginia, where I managed design, construction and inspection of bridge projects for various State Department of Transportation agencies.

I’m a 1984 graduate and holds a Masters in Structural Engineering from University of Virginia, Charlottesville, Virginia. I’m a licensed Professional Engineer in Virginia and Maryland.

What are the core elements of the BPETG mission?

The mission of BPETG is to advance and improve the state of the practice in the area of highway bridge preservation. We continue to work collaboratively with the States, four AASHTO TSP2 regional bridge preservation partnerships, TRB, industry and academia in developing products to promote bridge preservation.

Who are BPETG members? How is the activity of the group organized?

When I became the Chair in early 2016, I reorganized the membership for national outreach and focused on developing the strategic plan.  I created membership based on positions rather than specific individuals. For example, the current members include the chair, or their representatives, from four AASHTO TSP2 Regional Bridge Preservation Partnerships; chairs of three TRB Standing Committees on Bridge Preservation (AHD-37), Bridge Management (AHD-35), and Structure Maintenance (AHD-30); and representatives from the AASHTO Committee on Bridges and Structures (COBS) technical committees on Bridge Preservation (T-9) and Bridge Management, Evaluation, and Rehabilitation (T-18) and Bridge Technical Working Group, Committee on Maintenance (COM). In addition, we have members from academia and industry to get a full breadth of the preservation expertise.

Leadership of the BPETG is provided by FHWA with a co-chair position filled by a state DOT member either from AASHTO COBS or COM on a rotating two-year term basis. Members from academia and industry are appointed for three-year terms by the chair, with a possible reappointment.

Through this forum, FHWA solicits input from individual participants but does not intend to establish or utilize the BPETG as an advisory group in the interest of obtaining advice and recommendations under the Federal Advisory Committee Act (FACA). Decisions by the BPETG are not binding on the FHWA.

BPETG holds monthly virtual meetings via web and one face-to-face meeting per year.

What are BPETG goals and Strategic Objectives?

BPETG identified four Strategic Objectives:

1. Provide guidance on cost-effective bridge preservation strategies
2. Promote bridge preservation as a component of asset and performance management
3. Advise and assist in developing educational materials on bridge preservation
4. Foster a collaborative environment that encourages research and innovation

Under each Strategic Objective, we have several actions that we are trying to accomplish.

Preventive maintenance (PM) activities are essential for bridge preservation. How has the use of federal funds for PM evolved over years?

Use of Federal funds for preventive maintenance (PM) activities on Interstate highways was initially authorized in the Intermodal Surface Transportation Efficiency Act of 1991.  Subsequently, the National Highway System Designation Act of 1995 amended Section 116 of Title 23 U.S.C by extending PM activities eligible for Federal-aid highway. After each act, FHWA issued appropriate guidance to the states advising them of this eligibility. Specifically, in 2002, FHWA advised the use of Highway Bridge Replacement and Rehabilitation Program (HBRRP) funds on PM activities for Federal-aid highway using systematic process.

In 2008, the Safe Accountable Flexible Efficient Transportation Equity Act – A legacy for Users (SAFETEA-LU) Technical Correction Bill changed HBRRP to the Highway Bridge Program (HBP) and added systematic PM as an eligible activity. Bridge owners have taken advantage of the flexibilities in the HBP and have maintained their inventory in good to fair condition under constrained resources.

I understand that the new Bridge Preservation Guide is part of the Strategic Objectives. Could you comment about it?

The original Bridge Preservation Guide was published by FHWA in August 2011, when SAFETEA-LU was in effect and bridge repair and rehabilitation activities were funded by the Highway Bridge Program. This guide identified a “systematic process” as an eligibility of preventative maintenance (PM) actions for Federal aid funds. As a result, several Divisions signed agreements with their states as part of the stewardship and oversight agreements. These activities were not consistent among the Divisions.

The Moving Ahead for Progress in the 21^st Century Act (MAP-21) and the Fixing America’s Surface Transportation (FAST) Act allowed preservation activities to be eligible and there was a need to update the guidance and come up with a comprehensive list of PM activities for consistency throughout the country. Also, routine maintenance was never defined for bridges and what activities qualify as routine that are not eligible for Federal funds. The new guide that we released earlier this year (Ed Note:see linkage) provides those example activities as well. In addition, it provides guidance on how to establish a bridge preservation program if an agency desires to build one.

What are the other actions/programs that are being developed?

We are developing a series of pocket guides that will provide a focus on construction quality. Some of the topics that are currently being developed are: Thin Polymer Overlay Systems; Small Movement Bridge Expansion Joints; Bridge Cleaning; and Removal and Replacement of Bridge Coatings.

These guides are designed to address common errors and best practices to aid in preventing failures related to proper selection and application procedures. They are also expected to:

• provide proper installation/repair guidelines;
• provide a check-list for equipment and tools needed;
• identify limitations and restrictions including regional climates, traffic, and storage; and,
• identify potential failure mechanisms and how to avoid them.

The pocket guides will be electronic, posted on the TSP2 website, and will also be accessible via iOS and Android App. We hope to post the Thin Polymer Overlay Guide by November, and others are being reviewed by the group.

Another action item that we are currently working on is the “Deck Preservation Portal.” This project initiated from an original idea of developing a Transportation Asset Preservation Portal. The goal is to establish a web portal for repository of proven preservation actions to maintain bridges in good and fair condition. After discussions with BPETG members, it was decided to first develop a proof of concept focusing just on concrete bridge decks. The Deck Preservation Portal will be organized by component defect, cause, feasible actions, and cost information. FHWA is supporting the development and Iowa DOT is leading the project. We have formed a Technical Advisory Committee to lead this effort and plan to complete the project by fall 2020. The outcome of this project will be rolled into a pooled-fund project to develop the Transportation Asset Preservation Portal.

We are also working on providing guidance to bridge owners in the formation, execution, and evaluation of bridge preservation programs so as to meet their unique needs. FHWA has contracted with the University of Colorado to “Determine Agency Rules for Bridge Preservation: Developing a Decision Methodology.” The objectives of this project are to: 1) Compile the existing rules used by state DOTs, and 2) Develop a method for formation of decision rules for bridge preservation. This guidance appears to be essential for owners to reach MAP-21 and FAST Act requirements for maintaining infrastructures in a state of good repair at minimum cost. Bridges are complex structures with interdependent components for which a strategic use of bridge preservation actions is required.

The BPETG strategic plan that we developed in 2016 is almost three years old. As we continue to complete action items that we initially identified, we are also in discussions to update this plan to meet the current needs.

LINKAGE

FHWA 2018 Bridge Preservation Webpage

https://www.fhwa.dot.gov/bridge/preservation/

FHWA 2018 Bridge Preservation Guide

https://www.fhwa.dot.gov/bridge/preservation/guide/guide.pdf

Author: Lorella Angelini, Angelini Consulting Services, LLC

Second from the right: Rod Thornton with MDOT-SHA

Rod Thornton is the Maryland Department of Transportation – State Highway Administration’s (MDOT-SHA) Deputy Director of Structure Inspection and Remedial Engineering Division.  In addition to his responsibilities with MDOT-SHA, he is active with TSP2 being the Vice-Chair of the Northeast Bridge Preservation Partnership Committee. I had the opportunity to ask Rod a few questions about bridge preservation strategies at Maryland DOT.

What does bridge preservation entail at MDOT-SHA?

It is comprised of a number of programs that are all directed to preserving the integrity of the original bridges and eliminating emergency repairs.

A key program concerns bridge painting. The program, which advertises $12 million worth of painting projects every year, does not simply entail painting steel structural elements, but it also includes repairing deteriorated critical areas of the girders by plating, replacing leaking joint seals, and installing troughs under roadway joints.  This type of preservation work is included into the paint contract since paint scaffolding provides easy access to the areas to be repaired. By performing preservation work in parallel with painting, we eliminate the need to return to do these repairs in a following stage, which results in less of an impact to traffic and cost savings.  Funds above $12 million are added to the paint program in order to perform preservation activities.

Plating over severely deteriorated areas of a structural element, such as a beam, preserves the structural integrity of the element but also improves how long the paint system will last. The new “retrofit” plate provides a smooth surface that can be prepped to have the correct profile for proper paint adhesion. It is well-known that the long-term adhesion of a paint primer may be prevented if rust and other imperfections are not completely removed during the blast cleaning process and a proper profile of the blasted steel is not achieved. A good adhesion of the primer is essential for the intermediate coat and final coat to work.  Plating over the pitted areas of a beam with new steel allows for the creation of a good paintable surface profile, which in turn increases the longevity of the paint system. In areas that are subjected to a lot of moisture, like finger joints, the non-structural “retrofit” plates provide a layer of sacrificial steel while improving the adhesion of the paint.

Our paint program performs well, beyond the expected 20 years of steel protection. We are getting anywhere from 25 to 30 years out of the program.  The color of the top coat may fade, but the paint system still provides the steel protection that is needed to prevent corrosion.

Another important bridge preservation program at MD-SHA entails the use of latex-modified concrete overlays in order to preserve the deck thus avoiding or delaying its replacement.  The process starts with an evaluation of the chloride levels at the various depths of the deck. If a deck is in fair condition with concentration of chlorides near or just beneath the top mat of the deck reinforcement, we remove chloride-contaminated areas through hydrodemolition and we then cast a new latex-modified concrete overlay.  Since the early ‘70s, MDOT-SHA has required both the bottom and top rebar mats to be epoxy coated. Epoxy protects bars from corrosion induced by chlorides thus making it possible to reconstruct parts of the deck rather than replacing it.

MDOT-SHA is currently working to determine the best preservation actions for the old deck parapets that have high chloride concentration. We are looking into new types of sealers that contain chloride inhibitors to treat these parapets when the deck is partially reconstructed using latex-modified concrete thus preventing their replacement.

Another top preservation program at MD-SHA entails the installation of troughs under roadway joints where the seal is in NBI condition state 4 and 3.  We have set up a dedicated “open-ended” contract that allows us to assign a number of bridges to a contractor and get the trough installed once a bridge is identified. We also have a dedicated “open-ended” contract that allows us to wrap and strengthen the concrete structural elements of the substructure, such as caps and columns, with E-glass fiber reinforcement and coat these surfaces with an aliphatic polyurethane coating. Typically, we only wrap columns that are close, or adjacent, to roadways, thus creating a permanent water barrier from the salt spray generated by vehicles traveling past.

Since roadway joints are a source of deterioration for many elements of the substructure, such as bearings and beam ends, our newly designed bridges are built with no roadway joints or in a very limited number.

The last preservation program I would like to mention entails improving the protection of the steel tendons placed at the bottom of pre-stressed girders. We require a 4” clearance from the outside face of the girder instead of just meeting the 3” concrete cover required by AASHTO.  The additional clearance ensures that the tendons get adequately covered with concrete. There are known tolerances in casting of pre-stressed members that could end up reducing the cover of steel tendons that are close to the exterior surface.  We also include a design modification that increases the slope of the bottom flanges of AASHTO concrete girders so as to prevent accumulation of debris, bird droppings or bird nests.

Could you outline the key points of the bridge preservation strategy at Maryland SHA?

I would summarize the strategy in three points.  The first one involves the evaluation of Structurally Deficient (SD) and Fair rated bridges on the entire highway system with the goal to properly intervene on SD bridges and to prevent Fair rated bridges from becoming SD.  Every year two managers, one from the design and the other from the maintenance side of the bridge office, visit all bridges that are rated SD and also those bridges that had been rated 5 for one or more items (deck, superstructure, or the substructure) for more than 10 years. Once all these bridges have been looked at, we determine whether they are candidates for maintenance actions, preservation activities, major rehabilitation, or replacement. In doing so, we monitor all bridges that are in bad condition and determine actions to be implemented and scheduled.

A second element of the strategy entails examining common design or construction details that cause maintenance issues or are linked to potential deterioration problems.  If in the inspection reports there are details that show the presence of a recurring bridge defect, then proper recommendations are made to the designers so as to eliminate it. As an example, in the 1960s they used to weld stiffeners halfway from the top to the bottom of steel girders’ diaphragms. Once we recognized that these stiffeners induced fatigue cracking over 10 – 15 years, we informed the design team so as to find a more effective solution. A recurrent issue entails the accelerated deterioration that we experience with galvanized corrugated metal pipes used to carry water runoff with high concentrations of chlorides. There are many more examples of issues found in the field resulting in design changes, such as poorly performing roadway joint systems, multi plank bridge deck details, and parapet details.  Through the constant communication with the design office we were able to improve what is being designed for our new bridges.

The third element of our strategy calls for an actual and effective communication between the bridge design team and the office I am in charge of, which entails inspection, construction, and engineering design for maintenance.  We are in constant communication and we work together to decide whether bridges should be preserved thorough minor rehabilitation, major rehabilitation or replacement.  In principle, we can save and keep any bridge if enough money is available, but there are cases where it is not economical to rehabilitate a bridge.  When we decide to make a major investment to rehabilitate a bridge, the design team should agree that no future plans are going to be made to replace or enhance that bridge.  On the opposite, if the design team programs a bridge for replacement, then the maintenance team will focus on safety repairs only, since there is no reason to spend money on a bridge that will not be around for much longer.  Maintenance preservation actions are a priority for those bridges that are intended to be kept in service for a long time.  A lot of engineering judgement and experience is requested to know when to intervene and perform repairs and where we may have capacity and safety issues, such as beams not capable to carry the load or pieces of concrete falling on vehicles, if we do not intervene. This mix of engineering knowledge and experience is an essential component to ensure public safety, which is our most important goal.

What are your bridge preservation goals, both short and long term?

Our short term bridge preservation goal is to comply with the Governor’s mandate to reduce the number of Structurally Deficient bridges to zero. We are going to achieve this goal by combining repair, rehabilitation, and design actions. (Ed. Note: Out of the 2567 bridges managed by Maryland SHA, 67 are classified as Structurally Deficient, corresponding to 3% of the total).

Extending the service life of bridges is our long-term goal. If we can get 20 more years from a bridge by doing preservation actions, it makes sense to perform them.  Preservation actions can vary. If a bridge has a deck that is in fair condition with 20 more years of life in it, we focus on the key bridge elements that may need preservation, such as beams and substructure. If we prolong the service life of these elements, we eliminate the need to replace the bridge in the short term and can wait until the deck needs to be replaced. By bringing bridges to Fair or better condition, we extend their service life and have time to focus on those bridges that are in critical conditions and cannot be expected to last long without a large capital investments. We perform holding actions to ensure the safety of the traveling public.

Which challenges have Maryland SHA encountered in the implementation of the bridge preservation strategy?

We have an issue with environmental permitting, which is an impediment for pressure washing.

Other States have been able to get an agreement with their environmental people, for example scheduling power washing during heavy rain. In Maryland we can power wash only a limited number of bridges provided that we collect water.  Grime, grit, debris, and oils pollute water during power washing thus making water a hazardous material that is cost-prohibited to collect. As a consequence, it is difficult for us to maintain clean critical structural elements, such as trusses, that collect a lot of debris.

Do you have a success story that you would like to highlight?

In addition to the paint program, of which I have already spoken, I would like to mention the paved pipe invert contract.

We have restored over 300 galvanized corrugated metal pipes by installing a new reinforced grout invert.  The hoop design of the pipe is re-established by this structural design methodology which essentially consists of welding steel reinforcing bars in a pattern longitudinally and transversely along the inside length of the pipe and then pouring a 4” thick concrete grout invert over top. By adopting this methodology, we have repaired pipes anywhere from 3 ft to 20 ft in diameter located under major Interstates or throughout our highway system.  By not having to replace these pipes, we have saved a lot of money.  The typical cost of the grout repair method is $40/SF, which is typically 20+ times less costly than replacement.  We started by paving the worst pipes and we will continue until we have paved 1300 + pipes.

In my opinion a big bridge preservation success story in Maryland is arriving to the point of having sustained funding. We have always had funding for maintenance and repair, but it was a one-shot approach. We now have funding that allows for broadening the use of preservation actions and setting up systematic programs. The recent gas tax imposed by the State has been a tremendous windfall for the highway program in Maryland. It has allowed us to focus on the Governor’s goals to achieve zero SD bridges and to perform all improvements that are going on in the entire highway system here in Maryland.

How can TSP2 assist you with reaching your bridge preservation goals?

TSP2 is giving me a unique opportunity to develop personal relationships in the bridge preservation community. I can connect with representatives from other States to find out what their programs are like, what processes they follow, and what products they use.

All States are trying to achieve common bridge preservation goals as cost effectively as possible and with the least impact to the travelling public. TSP2 provides the means to achieve these goals by learning and replicating what the different States have done successfully.

LINKS

NCHRP Project 20 68A, Scan 15-03

Successful Preservation Practices For Steel Bridge Coatings

http://onlinepubs.trb.org/onlinepubs/nchrp/docs/NCHRP20-68A_15-03.pdf

SHA Paved Invert Specifications

https://www.roads.maryland.gov/OBD/11-08_SR-PI.pdf

Gregg Freeman, Business Development Manager with Kwik Bond

Author: Lorella Angelini, Angelini Consulting Services, LLC

Kwik Bond Polymers based in Benicia, California, is regarded as the largest supplier of polyester polymer concrete in the USA specializing in bridge overlays and concrete repairs. The company also offers thin epoxy overlays, High Molecular Weight Methacrylate (HMWM) concrete healer-sealers and High-Friction Surface Treatments (HFST), an innovative road safety countermeasure system.

To learn about Kwik Bond Polymers and its go-to-market strategy for bridge preservation, I spoke with Kwik Bond’s Gregg Freeman, Business Development Manager, and Merritt Hanson, VP of Sales.

What is your responsibility with Kwik Bond? When did you join the company?

Merritt Hanson, VP of Sales with Kwik Bond

Gregg: I joined Kwik Bond 6 years ago when I was approached by one of the founders of Kwik Bond after a presentation at a TSP2 Bridge Preservation Partnership meeting.

I work with the R&D Department for the development of new products, taking advantage of my 27 years of experience in the industry. I also work with DOTs in order to create specifications so as to be certain that contractors have proper information for installing our products correctly.

Merritt: I have been with the company for 12 years. My first experience with the polyester concrete technology took place in 2002 when I was with an overlay contractor. I met Kwik Bond founders at that time.  In 2006 they offered me a position as sales person in NY. I am now the VP for Sales focusing on the entire US market.

Can you speak of the evolution of Kwik Bond from a local company based in California to a  national competitor?

Gregg: The two founders of the company started working with Caltrans in the early 1980s.  At that time Caltrans was after “a more permanent solution” for concrete repair. As they decided to develop a new technology in partnership with the industry, they brought in industry experts who knew about polyester resins, methacrylates, and concrete construction. These experts became the founders of Kwik Bond Polymers. Once Caltrans started advertising the new technology for bid, they established Kwik Bond Polymers.  For a number of years Kwik Bond was both manufacturing polyester concrete and installing it. (Ed. Note: Nowadays Kwik Bond is exclusively a manufacturer. Kwik Bond works with local contractors for installations.)  The new polyester concrete technology has been managed well for many years in the State of California and it was well understood by Kwik Bond when the company decided to launch it nationally.

Merritt: Essential to the success of Kwik Bond Polymers is the fact that the polyester technology has proven that it works. The material bonds to the substrate, protects it over time and does not wear. Polyester technology simply does what it is supposed to do.

Kwik Bond has always taken care to verify that their materials are used in the proper manner to insure a correct application. This is also an important element of the success of Kwik Bond Polymers.

Can Kwik Bond be regarded as a successful example of collaboration between Agencies and industry?

Gregg: Yes, it has been a unique example of collaboration between an Agency and industry.  Caltrans did extensive research in the Lab and in the field by testing many different systems in search of technologies that could provide a solution to unique challenges.  At that time Caltrans had a large budget and highly skilled experts with a lot of freedom to push innovation to the limits, which also allowed them to bring in experts from industry.

Merritt: Once the polyester concrete technology was fully developed, Caltrans wrote specifications that were prescriptive and not so much performance-based.  Even though these specifications were functional to Caltrans’ needs, they could not tell everything about the material.  They informed about the individual components but the specifications did not underscore the interaction between these components, which is equally important. We were able to make the best use of Caltrans specifications because of our unique expertise with this technology.

Can you speak of polyester concrete? What are its primary applications and key properties?

Merritt: Polyester concrete can be used for a range of applications for bridge construction and preservation, first and foremost deck overlays, joint headers, concrete repair and regrading, such as building a wedge in approach slabs or overcoming extreme wheel path wear. For concrete repair applications you can pour up to 12 in. of polyester concrete in a single installation. I have actually poured up to 18 in.

Gregg: Polyester concrete has an exceptional resistance to wear. It is also completely impermeable thus preventing chlorides and contaminants from reaching the substrate. In comparison, high strength concrete has very low permeability but it is subject to cracking. It is well known that chlorides can enter even into very small cracks. This does not happen with polyester concrete. In the rare event a crack forms during a polyester concrete application, the crack does not grow. Then it can be easily and permanently sealed with a (HMWM) resin.

Merritt: I would say that the magic of Kwik Bond polyester concrete consists in the balance between its key properties, such as compressive strength, tensile strength and tensile elongation. You can actually boil it down to the balance between tensile strength and modulus of elasticity. At Kwik Bond we do not brag about exceptional properties of polyester concrete. Some competitors promote 20,000 psi compressive strength of their technology, but you actually do not want it. You want a balancing act: enough strength to keep the material from wearing and enough flexibility to handle the normal motions of a bridge deck. Kwik Bond polyester concrete provides this kind of balance. We therefore like to underline the correct balance of properties of polyester concrete, not its “high” something.  Let me underscore one more time that a carefully designed balance between key properties is at the core of the successful installations of Kwik Bond polyester concrete.

What about fast setting that allows quick traffic reopening?

Gregg: Fast setting is a very important Kwik Bond products’ feature, especially for polyester-based HFST applications. This technology allows return to traffic in 2 hours even in cooling conditions.

A key element for understanding why Polyester Polymer Concrete (PPC) provides such long-lasting installations is its thermal compatibility with the concrete substrate. Because Kwik Bond polyester concrete has such a large volume of aggregate relative to its resin, it has a good thermal compatibility compared, for example, to thin overlays, which expand and contract at a high rate. Our system is much closer to concrete than alternative solutions. It therefore reduces, or eliminates, thermal stress at the bond line.

Merritt: Certainly fast setting gets the attention, but the reason people continue to use our polyester-based concrete is because it works. It is a robust, forgiving material that works in a wide variety of cases, not just in niche conditions.

What are the challenges that you are facing in promoting this technology?

Gregg: People who are new to the technology tend to oversimplify it. Based on our success, they think that it is easier than it actually is.  They make mistakes that are detrimental to the good name of the polyester-based concrete technology.

Merritt: To me the biggest challenge is information. Despite the fact that polyester concrete technology has been used consistently  since 1983, it  is still new to a lot of people, who do not know what it can do for them and what it has done elsewhere successfully.

Materials that use resin as a binder are widely accepted nowadays, yet they are not gray or black, I mean they are not Portland cement-based or asphalt. These materials belong in a category of their own that it is still looked with diffidence by some people.  So for us the first challenge is to get the message across that our polyester-based technology does work. And even though there is no water/cement ratio to specify, the material can still provide successful installations.

What about the challenge of promoting this new technology to DOT Agencies?

Merritt: When I joined the company, Kwik Bond was working in just a few States in the West. Since I live in New York, I concentrated my efforts in the North East. I cannot tell you how unimpressed people were of the company’s success in California. The fact that the polyester technology had been used to overlay some of the biggest bridges in California was not really a factor. Breaking the barrier was very difficult. How did I go through it? I contacted DOT maintenance teams and did a lot of repair patches for free to show how the product works in the field.  I also met designers who trusted the technology and agreed to specify jobs. Engineers almost universally want to “kick the tires”. They want to see that the product works, even if it is on a small scale application. And I realized it early on.

Gregg: We took a small step approach. We found champions who were interested in bringing the technology forward.  With their help we put the product down and we started building a success story in almost each State. This strategy really works unless you find a State where a similar technology had failed in the past, or, even worse, had caused a safety hazard. It is almost impossible to enter such a State. Nobody wants to take the risk of adopting a technology that has a bad reputation, no matter how much the new technology is different from the one that had caused problems in the past and proved to be successful.

It seems that overcoming bad reputation is an important issue in dealing with DOTs.  Is this a challenge for Kwik Bond?

Merritt: This is really a big challenge for Kwik Bond. Since people think that polyester concrete technology is easy, there are occasionally contractors or suppliers that try to piece the system together. Unfortunately, there is more to it than what they see initially.  It is not so easy to provide long-term preservation and an outcome that has been proven over time.  Just because someone claims to meet the specs, it does not mean that the material will be able to perform over time.  Symbolic goods are not equivalent to the real thing.

Polyester concrete is an engineered composite system where the single components need to be compatible in order to work together properly. The system is certainly more than purchasing a series of ingredients and mixing them in the job site. It does not work in that way.

When a polyester concrete mix is put together by people who do not have  adequate expertise and knowledge, applications can go poorly. This can give a bad name to the technology thus disrupting what we have built. For this reason, we have had to overcome reputation problems in a number of States. Typically somebody else comes in, tries to do what we do, and does it so poorly that all brands of polyester concrete, Kwik Bond included, can be banned for years.

Our way to go to market is to control applications and avoiding overselling. We only sell when we are sure that the product is the right solution. For this reason we are reluctant to sell through distribution and we prefer selling directly to contractors

Gregg: Polyester concrete is essentially a mix of two blends of aggregate and the resin. Kwik Bond Polymers specifications say that there should be a preliminary research showing that the components are compatible when mixed together. Very few people understand the meaning of this requirement. Formulations are thrown on the market without properly testing the compatibility of the ingredients.  This does not happen with Kwik Bond Polymers since we have an unmatched level of knowledge and experience with polyester concrete technology.

LINKAGE

Kwik Bond Polymers website

http://www.kwikbondpolymers.com/

FHWA LTBP Summary—Current Information on the Use of Overlays and Sealers

http://www.trb.org/Main/Blurbs/176789.aspx

SEBPP 2017 Presentation: Polyester Polymer Concrete Overlays in North Carolina

John Buxton with Maine DOT

Author: Lorella Angelini, Angelini Consulting Services, LLC
I recently spoke with John Buxton, Bridge Maintenance Engineer / Deputy Chief Engineer at Maine DOT.  He is in charge of the Bridge and Structures Maintenance Division at the Bureau of Maintenance and Operations. In addition, he is connected to the executive office as the Deputy Chief Engineer. John is fully committed to bridge preservation. His many years of experience in this field make him a go-to person with TSP2.

What does bridge preservation entail at Maine DOT?
Bridge preservation currently represents 70% of Maine DOT’s maintenance budget. While in the past we used to do a lot of rehabilitation and restoration type of work, currently preservation is the primary focus for the maintenance department. Preservation entails activities such as replacing and repairing joints, making sure that all joints are sealed, sealing concrete with water repellents, painting bearings and beam ends, and keeping concrete wearing surfaces in good condition. We are trying to address the deterioration of bridge elements before it becomes a problem. It is evident that it is better to spend a few dollars in preservation than thousands of dollars in restoration.

Does your 70% of maintenance budget include all preservation expenditures at Maine DOT?
In addition to maintenance, also the capital side has a budget for preservation activities, which mainly entail full painting projects. We are treating concrete with silanes, not only the deck but also vertical surfaces, such as piers adjacent to travel ways, back walls, and all exposed concrete.

The capital money is obviously not as aggressive in preservation as maintenance money. The capital side probably spends 25 – 30 % of their funds in preservation while the rest is reconstruction and bridge replacement.

Getting the capital people, who focus on new bridge construction, to invest funds on preservation activities has been a major shift in the way Maine DOT operates.  It is a combination of preservation, construction and reconstruction that allows maximizing investments for the bridge infrastructure.

What are the key points of the bridge preservation strategy at Maine DOT?
Our main strategy is to keep bridges in good condition by doing preservation activities. We are getting out of the “worst first” type of mentality, even though we continue to take care of bridges that are deteriorated beyond the practical maintenance point.

If you talk with other representatives from the TSP2 Bridge Preservation Partnership, you will find that they are using the same approach.

Do you have any statistics that show the benefits of a bridge preservation strategy?
The benefit of preservation is probably one of the hardest things to capture. For example, when you seal concrete it is hard, almost impossible to predict, whether the concrete is preserved for 20 or 25 years. In terms of NBI Bridge Inspection Ratings, when you seal the concrete of a pier, you do not change the rating of the pier. Let’s say the pier is in a condition state 6. By sealing the concrete you hopefully have kept the pier in that condition state for a longer time, which does not show up in graphs or statistics. It is really difficult to quantify the benefits of preservation actions.

Is it challenging to convince people of the benefits of preservations?
Yes, building a new bridge always carry the headlines. However, the political flavor has changed in Maine and around the Nation. People understand that it is worth preserving bridges, especially when they see the tremendous cost for a new bridge. Spending a fraction of that cost to do actions that can preserve an older bridge and get 30 – 40 more years of life out of it is evidently the proper way to go in most cases.

What are your goals with bridge preservation?
In line with the National Highway System guidelines, our primary goal is to eliminate all condition 4 , corresponding to poor condition, for bridge elements.  However, our goal is not only based on numbers but also on a case by case evaluation. Let’s say that we have an abutment that is in a condition state 4. It does not mean that the abutment is unsafe. It just means that the abutment is not in a good condition. It may have been in that condition for 20 years and it may be able to provide another 10-15 years of service life in that condition. Sometimes it is necessary to be aggressive on a bridge element, sometimes not.  What is important is to evaluate the impact of the element on the functionality and the safety of the bridge.

Can I say that that you are in favor of a selective approach?
If you just look at numbers, they are pretty sterile; they do not tell you the whole story. It takes skilled, talented, knowledgeable professionals within each State Agency to evaluate risks related to the condition state of bridge elements. To be able to quantify and qualify these risks is a key knowledge that ultimately keeps public safe.

You do not want to spend funds just to make the numbers look good.  You want to do the right thing for your bridge inventory.  If you can postpone expenditure for 15 years without jeopardizing safety and function, then this is the right thing to do in my opinion.

Who takes decisions related to bridge elements at Maine DOT?
We take decisions in a bridge committee that comprises of three legs: bridge maintenance, bridge design and construction, the so called capital program, and bridge management. It is what we call Maine DOT’s bridge community.  We know each other. A lot of us have worked together for as long as 30 years.

I am also part of a posting committee at Maine DOT that takes decisions on bridge weight restrictions. If a bridge does not meet a certain level of capacity based on bridge ratings, we evaluate whether we post the bridge or we strengthen it. In some cases, we do research, such as load testing, cutting coupons out of the steel to see if it is still strong, or cutting reinforcement steel in concrete to see strength can be added.

Some posting can be restrictive thus impacting community and commerce.  Bridges in rural areas usually need fewer restrictions since they just carry fire trucks and light vehicles. Even though many bridges in Maine are in good condition, they were designed 60 years ago for a much lighter type of vehicles.  Over 50% of Maine bridge inventory is more than 50 years old.

We spoke of the challenge of making people aware of bridge preservation benefits. Are there other major challenges?
The availability of experienced, qualified workers is another major challenge for bridge preservation. Craft people are not readily available as they once were. This challenge is not peculiar to Maine but rather a nationwide issue.

Do you do in-house maintenance work?
Two years ago Maine DOT started contracting maintenance jobs out. We had more money for maintenance than in the past but not enough people to do the job. We therefore decided to contract out using those additional funds. It was a little clunky at first because we had never contracted jobs out before.  The capital department had always done all the contracting for bridges at Maine DOT. We had to learn how to put out contracts and they are small contracts, generally under $200,000.

With the increased funding, do you have enough money for all preservation work at Maine DOT?
In 2007 and 2014 we developed two reports called “Keeping our Bridges Safe” (see Linkage – Ed. Note). Those reports recognize the need of spending $140 M/year for bridge preservation. However we get on average $105 M/year. As a result of being we remain $30 – 40 M/year short of spending requirements, at Maine DOT we are accumulating a spending deficit of $90 – 120 M in the length of time of 3-4 years.

Is there any bridge preservation success story you would like to share?
I think our biggest success story is that the entire bridge community at Maine DOT is on board with bridge preservation and really sees the value of it.

Painting may not improve the NHS condition rating of a superstructure, sealing concrete may not improve the NHS condition rating of a substructure; however these are important actions to keep bridges in a good condition. As an analogy, regularly changing the engine oil does not modify the way one drives a car but it makes a big difference in the longevity of the cars’ engine.

Does TSP2 assist you in reaching your bridge preservation goals?
I remember when Ed Welch from New Hampshire DOT, Pete Weykamp from New York DOT and Everett Barnard, my predecessor at Maine DOT, used to meet in New Hampshire with maintenance personnel. These three people first recognized the need for bridge preservation to have its own forum. So my hat goes off to them for pushing the preservation idea and setting up the conditions for having the Partnerships.

To me every year TSP2 Bridge Preservation meetings are better. Communication between bridge preservation practitioners is improving and we have more proficient people representing manufacturers. I can call up a number of engineers that are part of the Partnership and ask: have you tried this? Have you got this problem? What do you do to solve it? The network is just phenomenal.

There is a great value for bridge preservation practitioners to connect with product manufacturers’ people at the TSP2 Bridge Preservation Partnership meetings. Bridge practitioners can speak with different manufacturers and compare their products. There is also an opportunity for competitors to confront their products. Manufactureres also have avenue where they can speak with each other and potentially start collaborations for putting together different products and technologies in order to solve bridge preservation problems. TSP2 sets the stage for creating synergies between product manufacturers.

LINKAGE

Maine DOT
http://maine.gov/mdot/

“Keeping Our Bridges Safe” 2007
http://www.maine.gov/mdot/publications/docs/plansreports/Keeping%20Our%20Bridges%20Safe.1107.pdf

“Keeping our Bridges Safe” 2014
http://digitalmaine.com/cgi/viewcontent.cgi?article=1083&context=mdot_docs