Canada Bridge in Ormand Beach

The Problem

The SR-40 bridge over the Halifax River at Ormond Beach, Florida is 1,923 feet long and includes 19 spans. The main span is 123 ft. long and has a vertical clearance of 65 ft. The bridge is 93?8?wide and includes two travel lanes in each direction, inside and outside shoulders, and an outside sidewalk for each travel direction.

The foundations for the two main span piers are driven steel H-pile supporting a pile cap. A 75-ft. long x 25-ft. deep x 10-ft. thick crash wall over the pile cap supports the columns of the bridge. The major portion of the crash wall is submerged under water with only 5 ft. above the water level.

The subject bridge replaced a bridge that was situated along the northern portion of the current structure. The bridge was constructed in a sequence that required construction of Phase 1 of the new bridge prior to demolition of the old bridge. After completion of Phase 1, traffic was diverted to the new bridge and demolition of the old bridge and Phase 2 construction of the new bridge proceeded. The project was completed in 1983.

Cracking of the crash wall was first noticed in January 1986. The number of cracks and their magnitude gradually increased to include cracks up to ?inch wide in 1995. The severity of the cracks and concrete spalling were alarming and required immediate attention.

An investigation of the causes of deterioration revealed that the cracking was due to differential settlement between the two phases of construction and a design error.

Conventional post-tensioning was used to repair one of the piers, while the second pier was repaired with the MAS2000 Fiber Wrap System.


Inspection of Cracking and Deterioration After De-Watering	Close-up

The Solution

Application of MAS2000

The deteriorated crash wall was first analyzed utilizing a non-linear finite element program. The results of the analysis were used to design the optimum repair procedure.

Rehabilitation began by cleaning and chemically treating all corroded reinforcement to prevent further corrosion. In many cases, concrete had to be removed so that the full length of damaged steel could be exposed and treated, thus minimizing the long-term effects of corrosion.

All unsound concrete was removed prior to restoring the wall to the original shape, using a high strength quick setting concrete. Following the concrete cure, the surface of the wall was prepared according to SDR specifications. The MAS2000 Fiber Wrap System was then applied to the concrete and wrapped around the entire section, forming a composite collar.

The original appearance of the structure was restored and enhanced by painting the composite laminate with a specially designed waterproof membrane with a ultraviolet (UV) coating. The cost of the repair was considerably lower than that of the conventional repair method.

This project is considered to be the largest single application of structural rehabilitation using composite laminates. The structure was rehabilitated in 1997 and the repair has been performing well ever since.

Wrapping of Section

The MAS2000 repair system proved to be economical, quick and easy to apply.