Technical Specifications

Bridge Length: 23 ft. 3 in.
Bridge Width: 27 ft. 9 in.
Clear Span: 21 ft. 3 in.
Weight: ~25,000 lbs.
L/d: 1,165
Number of Sections: 3 (23 ft. 3 in. long by 9 ft. 3 in. wide each)
Standard: in excess of AASHTO Standard HS-20
Installation Time: ~8 hours
Manufacturer: Kansas Structural Composites, Inc., 2649 E. Wichita, Russell, Kansas 67665
Location: 3 miles east of Russell, Kansas on county road
Sponsor: Transportation Research Board
Construction: Fiber Reinforced Polymer Honeycomb (FRPH) Panel with a 0.750 inch polymer
concrete wear surface
Estimated failure load: 1,500,000 lbs.

Awards:

1. Best in Infrastructure - International Composite Expo, Nashville, TN - January 1997
2. Counterpoise Grand Design Award - International Composite Expo, Nashville, TN - January 1997
3. R&D 100 - Chicago, IL - October 1997

Photo Gallary

The No-Name Creek Bridge Development Team:

Funding Organizations.

Department of the Army
Corps of Engineers
Construction Engineering Research Laboratory (CERL)
2902 Newmark Drive
Champaign, IL 61821-1076
Contact: Mr. Richard Lampo (217) 373-6765; fax (217) 373-6732

CERL provided a $55,000 contract to investigate the use of post consumer waste in the fabrication of light-weight, heavy-duty, structural composites. This contract covered the period of 1993-1996 and resulted in the focus on bridge building using structural panels. Fiber reinforced polymer honeycomb structural panels numbering well in excess of one hundred were designed, fabricated, and tested under this project. To date, this represents by far the largest body of test data for infrastructure composites and establishes a solid technical engineering basis for these materials.


National Academy of Sciences
National Research Council
Transportation Research Board
Innovations Deserving Exploratory Analysis Program
2101 Constitution Avenue, N. W.
Washington, D. C. 20418
Contact: Dr. K. Thirumalai (202) 334-3568; fax (202) 334-2003

In 1996, the IDEA program awarded KSCI a grant of $95,000 to utilize the engineering data previously developed to design, fabricate, proof test, and install a short-span bridge over No-Name Creek on a public road three miles west of Russell, Kansas.

Russell County Support.

Russell County Highway Department
4288 US Highway 40
Russell, KS 67665-9019
Contact: Mr. Robert L. Hoback - Director (913) 483-4032; fax (913) 483-4852

The Russell County Commissioners voted to participate in the bridge project and provided $20,000 worth of services in preparing the site. Mr. Hoback supervised the proof testing of the bridge and the installation. He served as co-principal investigator of the IDEA project and his services were essential to making a success of the bridge project.

Russell County Economic Development
610 Main Street
Russell, KS 67665
Contact: Mr. Ned Webb, Director (913) 483-6960; fax (913) 483-4535

Mr. Webb was one of the key reasons that KSCI was chartered in Kansas and located in Russell. He provided the many pieces of information that was necessary in getting a new technology firm located in a smaller community. He also provided the initiative to launch the bridge project in the community.

State of Kansas Supporters.

Kansas Department of Transportation
Bureau of Materials and Research
Materials and Research Center
2300 Van Buren
Topeka, KS 66611-1195
Contact: Mr. David A. Meggers, R&D Engineer (913) 291-3845; fax (913) 296-2526

Mr. David Meggers provided a continuing stream of advice, recommendations, and assistance throughout the project. His services were extremely valuable in providing interpretations of bridge code HS-25 as applicable to composite materials.

Kansas Technology Enterprise Corporation
214 S. W. Sixth
Topeka, KS 66603
Contact: Dr. Kevin Carr, V.P. Applied Research (913) 296-5862; fax (913) 296-1160
Mr. Clyde Engert, V.P. Innovation & Research

Both Dr. Carr and Mr. Engert supplied valuable information for KSCI as it became established in Kansas. Their advice continues to direct our marketing efforts.

Industry Contributors.

Alpha Owens/Corning (AOC)
950 Highway 57 East
P. O. Box 610
Collierville, TN 38027-0610
(901) 854-2800; fax (901) 854-1183
Contact: Susan Romans (419) 248-8479

AOC donated three different thermoset polyester and vinylester resins. They donated over 12,000 pounds of materials. In addition, AOC personnel provided consulting on polymer selection and made recommendations as to the additives to be used.

Vetrotex Certainteed Corporation
Fiberglass Reinforcements
750 E. Swedesford Road
P.O. Box 860
Valley Forge, PA 19482
Contact: Mr. David Sharpe (610) 341-7384

Vetrotex Certainteed Corp supplied all the fiberglass used in the Russell County bridge construction at no cost. The total amount was in excess of 10,000 pounds.

Brunswick Technologies, Inc.
43 Bibber Parkway
Brunswick, Maine 04011
Contact: Mr. Mark Cavon (207) 729-7792

Brunswick Technologies, Inc. donated unaxial glass fiber rovings in stitched mats of a special configuration designed to meet bridge requirements. Materials consulting services were also provided.

ITW Plexus
21415 Civic Center Drive
Southfield, MI 48076
Contact: Mr. Gregory Rose (800) 323-0451

ITW Plexus supplied several adhesives for bonding the core to the panel surfaces and to attach the panel connections and closeouts. In addition, they provided technical services in the selection of these adhesive materials.

Paul A. Carter
8342 Yarrow Ct.
Arvada, CO 80005
(303) 425-0936; fax (303) 421-1284

Mr. Carter provided computer services, including technical drawings and desk top publishing, along with business marketing consulting.

University Independent Testing.

Kansas State University
Mechanical Engineering Dept
319 Durland Hall
Manhattan, KS 66506-5106
Contact: Professor Hugh S. Walker (913) 532-2616; fax (913) 532-7057

Professor Walker tested over 125 FRPH specimens in compression, flexure, and shear. It is fair to say that Professor Walker laid the engineering data foundations for the use of FRP honeycomb materials for heavy-duty, light-weight, infrastructure applications.

University of Nebraska - Lincoln
Department of Civil Engineering
W-348 Nebraska Hall
Lincoln, NE 68588-0531
Contact: Professor Atorod Azizinamini (402) 472-5106; fax (402) 472-8934

Professor Azizinamini has tested several FRP honeycomb specimens including a deck section 22 feet long by 12 inches wide and 14 inches deep. His investigations of KSCI materials continues as he studies the effects of freeze/thaw cycles on the strength of fiber reinforced polyester resins. These specimens are to be used in restoring a historical bridge.

University of California, San Diego
Civil Engineering Department
Structural Systems
9500 Gilman Drive
La Jolla, CA 92093-0085
Contact: Professor Geza Nagy (619) 350-1837; (619) 552-8420

Professor Nagy tested three honeycomb structural panels fabricated by KSCI and found them to be superior on a strength to weight basis to other panels tested at this laboratory.

University of Nebraska - Lincoln
Department of Civil Engineering
W-348 Nebraska Hall
Lincoln, NE 68588-0531
Contact: Professor Madgi A. Khalifa (402) 472-8771; fax (402) 472-8934

Professor Khalifa tested a series of smaller FRP honeycomb panels to be used for a proposed 900 foot long foot bridge. The project was not constructed and work terminated in 1995. However, the test results were useful to KSCI.

Design Review Team Members.

Sponsor Representative.

Dr. Inam Jawed, Senior Program Officer
Transportation Research Board
National Research Council
National Academy of Science
2101 Constitution Ave., N.W.
Washington, D.C. 20418

office:
2001 Wisconsin Ave., N.W.
Washington, D.C. 20007
Phone (202) 334-1430
FAX (202) 334-2003

Kansas Department of Transportation Representative.

David A. Meggers, P.E.
Research Development Engineer
Kansas Department of Transportation
Bureau of Materials & Research
Materials & Research Center
2300 Van Buren
Topeka, KS 66611-1195
Phone (913) 291-3845
FAX (913) 296-2526

Russell County Highway Department.

Robert (Bob) Hoback
Road & Bridge Supervisor & Co - P.I.
4288 U.S. Highway 40
Russell, KS 67665-9019
Phone (913) 483-4032
FAX (913) 483-4852

University Participants.

Professor Atorod Azizinamini
Department of Civil Engineering
Nebraska Hall W-348
Lincoln, NE 68588-0531
Phone (402) 472-5106
FAX (402) 472-8934
(represented by Tom Ahlschwede)

Professor Tom Harmon
Department of Civil Engineering
1 Brookings Drive, Campus Box 1130
Washington University
St. Louis, MO 63130
Phone (314) 935-4536
FAX (314) 935-4338

John Held
6343 W. 59th
Manhattan, KS 66502
Phone & FAX (913) 539-0216
Associate of Professor Hugh S. Walker

Geza Nagy, PhD
Principal Development Engineer
Structural Systems, 0085
University of California, San Diego
La Jolla, CA 92093-0085
Phone (619) 534-4344
FAX (619) 534-6373

Professor Max L. Porter
Department of Civil & Construction Engineering
Town Engineering Building
Iowa State University
Iowa, IA 50011-3232
Phone (515) 294-7456
FAX (515) 294-8216

Dean Donald E. Rathbone
Dean of Engineering
Kansas State University
146 Durland Hall
Manhattan, KS 66506-5104
Phone (913) 532-5590
FAX (913) 532-7810

Professor Hugh S. Walker
Mechanical Engineering Department
Durland Hall #319
Kansas State University
Manhattan, KS 66506-51
Phone (913) 532-5610
FAX (913) 532-7057


Materials Suppliers.

Michael J. Michno, Jr.
Manager, Government Contracts and Development
Amoco Performance Products
4500 McGinnis Ferry Road
Alpharetta, GA 30202-3914
Phone (770) 772-8545
FAX (770) 772-8289

Rick Paver
Technical Manager, Composite Business Development Team
Reichhold Chemicals, Inc.
2400 Ellis Road
Durham, NC 27703-5543
P.O. Box 13582, M/S 374A
Research Triangle Park, NC 27709-3582
Phone (919) 990-7530
FAX (919) 990-7514

Engineering Consultants.

Jerry D. Borgstadter, S.E.T.
Kirkham Michael & Associates
308 North Douglas
P.O. Box 4
Ellsworth, KS 67439
Phone (913) 472-3163
FAX (913) 472-3817

James D. Pickett, P.E. & L.S.
5 Peoria Street, Suite 109
P.O. Box 879
Louisburg, KS 66053
Phone (913) 837-4122
FAX (913) 837-4133


Kansas Structural Composites, Inc.

2649 E. Wichita
Russell, KS 67665
Phone (785) 483-2589
FAX (785) 483-5321
Stephen Gill, Project Engineer
John B. Kunz, V.P. Production
Jerry D. Plunkett, President/CEO
Residence: 2150 S. Josephine St, Denver, CO 80210
Phone (303) 722-8258


Russell County Economic Development.

Ned Webb
Director
610 Main St.
Russell, KS 67665
Phone (913) 483-6960
1-800-658-4686
FAX (913) 483-4535


Kansas Technology Enterprise Center.

Dr. Kevin M. Carr
Vice President, Applied Research
214 W 6th St., First floor
Topeka, KS 66603-3710
Phone (913) 296-5862
FAX (913) 296-1160

Left to right: Dr. Jerry Plunkett (KSCI), Steve Gill (KSCI), David Meggers (KDOT), Jon Held (KSU), Dr. Hugh Walker (KSU)