The ZellComp deck has been installed on seven bridges. Five of these installations have been completed in the past two years. In the summer of 2011, the ZellComp deck will be installed on the Morrison Bridge in Oregon. At over 17,000 square feet, this will be the largest FRP bridge deck ever installed in the United States.

October 2010 – Broadway Bridge in Portland Oregon

This project involved a partial deck replacement for the historic Broadway Bridge in Portland, Oregon. About seven years ago, the City of Portland selected another company's FRP deck to be used on the movable section of the Broadway Bridge. The City recently decided to install rails for street cars on this bridge, which required removal of part of the existing FRP deck. The ZellComp deck was selected as the replacement deck—primarily due to the system's growing track record and its ability to be adjusted onsite. This project was unusual, because the ZellComp deck had to be installed between the new rail lines. The ZellComp installation was approximately 3,470 square feet. The installation contractor was Hamilton Construction, serving as a subcontractor to Stacy and Witbeck, Inc. The engineering firm of record for the deck replacement portion of the work was Hardesty & Hanover and for the bridge project was David Evans and Associates, Inc.

The following pictures show some highlights from this successful installation:

...........................................................................................................................

Installation of Bottom Sections

Installation of Top Sheets

June 2010 – Penn State

The ZellComp deck was installed on a pedestrian bridge at Penn State. This was the first pedestrian bridge deck installation for ZellComp.

...........................................................................................................................

January 2010 – Redstone Arsenal, Alabama

The ZellComp deck was selected by the Army Corps of Engineers to replace a corroded concrete deck on a bridge at the Redstone Arsenal, located in Huntsville, Alabama. This bridge is 4000 square feet.

The following pictures show the details of this recent installation:
...........................................................................................................................

Installation of Bottom Sections

................................................................................................................................................................

Installation of Top Sheets

November 2009 – Lafayette, Tippecanoe County, Indiana

The ZellComp deck was selected to replace a corroded concrete deck. This bridge had a crown. Before this installation, the ZellComp deck was tested by Purdue University.

The following pictures show the installations steps of this recent installation.

................................................................................................................................................................

August 2009 – Belle Glade, Florida

This ZellComp deck replaced an open steel grating that had required constant maintenance due to corrosion. This bridge is skewed, and the deck was tested by the Florida DOT prior to this installation.

November 2007 Installation – Bradford, Vermont

In November 2007, ZellComp installed a 5-inch ZellComp^® Decking System on a truss bridge in Bradford, Vermont. Details of this successful installation are shown below.
................................................................................................................................................................

Attach Bottom Sections

The following pictures show the details of the installation of the ZellComp bottom sections on the bridge in Bradford, Vermont.

	A crane was used to place each bundle of several bottom sections on the bridge.
After the bundles were placed on the bridge, no crane or bobcatwas needed to move the sections into place, as the bottom sections were easily moved by hand	Installation of Bottom Sections completed.

Installation of Top Sections completed.	ZellComp also worked with Kwik Bond Polymers to apply a wear surface to the bridge deck in Bradford.

.................................................................................................................................................................

ZellComp’s First Installation – Tangier Island, Virginia

ZellComp successfully completed its first bridge deck installation in November 2006 on Tangier Island – a small island in the Chesapeake Bay. The logistics were extremely challenging. All materials and necessary supplies were delivered by barge. Every small detail was important, because there are very limited supplies available on the island, and transportation on and off the island is quite limited.

ZellComp met the challenges, worked closely with the state department of transportation and the contractor, and completed a successful installation.

ZellComp’s two-part patented system offers ease of installation and flexibility to make adjustments onsite – which are two key advantages over other composite bridge decks.

.................................................................................................................................................................

Attach Bottom Sections

The following pictures show the details of the installation of the ZellComp bottom sections on Tangier Island, Virginia.

.................................................................................................................................................................

Connect Top Sections
Mechanical fasteners are used at the site of installation to attach the top sections to the bottom sections and to join adjacent bottom sections. Fasteners are drilled through the top sheets and into the flanges of the T-Sections in the bottom sections.

.................................................................................................................................................................

Upcoming Installations

ZellComp has an upcoming installation in Portland, Oregon, and is in discussions with Departments of Transportation and county engineers in several states, as well as engineering firms, contractors, and commercial entities.

.................................................................................................................................................................

Representatives from the Federal Highway Administration and the Virginia Department of Transportation visited the Tangier Island construction site during installation of the ZellComp^® Decking System.