Lighter and Stronger
"Another Bridge Protected.
Over 20 Million Sq. Ft. and Counting..."
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The decision was made to replace
the old deck with a 5/8" thick
orthotropic steel plate deck.
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Since its opening in 1939, nearly 2 billion cars have crossed the Bronx-Whitestone Bridge, connecting the Bronx to Queens. With a current ADT exceeding 120,000, the Triborough Bridge and Tunnel Authority (TBTA) had the challenge of making the deck both lighter and stronger to accommodate the ever increasing traffic demands.
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| Quality control adhesion tests of the installed system indicate 800+ P.S.I. bond strength to steel. |
With a main span of approximately 2,300 feet and approach spans of over 700 feet, the total deck area to be replaced covered more that 290,000 square feet. Additionally, the new challenge was to protect this new 5/8" think orthotropic steel deck from the elements: rain, snow, and salt among other corrosive materials.
What was needed was a resilient system capable of expanding or contracting with the steel during extreme weather conditions, as well as tough enough to withstand the constant pounding of millions of vehicles per year. Research at the University of St. Louis showed that the POLY-CARB FLEXOGRID System provided a superior solution for these extreme conditions.
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The orthotropic decks were manufactured in Brazil. To achieve 100-percent success, this project required that POLY-CARB provide extensive and continuous training along with customized solutions.
Ultimately, this attention to detail provided the highest standards for the FLEXOGRID System installed on each of the more than 450 panels. |
The manufacture of orthotropic deck panels and shop application of the FLEXOGRID System occurred in Brazil. The panels were then shipped to New York for the field welding and joint installations. The balance of FLEXOGRID was applied over the weld joints in the field and the installation has been subject to grueling traffic since 2006.
What is FLEXOGRID?
It is a thin (1/4”), yet flexible, overlay system, with performance proven up to 15 years. The hybrid nature of this patented system, including the unique, stable nature of the copolymer, provides the molecular stability necessary for low-temperature flexibility and long-term performance. Engineers have reported skid numbers for FLEXOGRID as high as 70 when new, and as high as 55 even after eight or nine years of service.
FLEXOGRID is:
- Thin and lightweight, yet tough and flexible
- Designed for long-term performance
- The most cost-effective solution in terms of life-cycle costs
- Impervious to moisture or chloride
- Free from hydrogen ions
- Safe; free of toxic solvents
- Quick and predictable
To learn more about this project and how FLEXOGRID can protect your bridge decks, contact POLY-CARB at 1.800.CALL.MIX or flexogrid@poly-carb.com.
 Continue to WIN with POLY-CARB:
POLY-CARB has long been recognized at trade shows with the matching numbered badge contest. We have extended this program online. If your badge number is 5975, contact us at
winner@poly-carb.com for your prize. |
Over the last 34 years, POLY-CARB has become a leader in manufacturing premium quality epoxy system solutions and materials that result in unparalleled value, performance and service.
More information about POLY-CARB is available at www.poly-carb.com. |
Location:
Bronx-Whitestone Bridge, New York
Bridge Type:
5/8" thick orthotropic steel plate deck
Size:
290,000 Sq. Ft.
Ready for Traffic:
Over 450 panels were welded together in stages so that service was never suspended.
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