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SUMMARY
Abstract
INTRODUCTION
Several high-profile incidents have focused attention on deficiencies in the
public works infrastructure of the U.S., which includes bridges, tunnels,
highways, roads, railroads, airports, canals, dams, dikes, artificial harbors,
and some pipelines. The most recent such incident was the collapse of the
Interstate 35-W bridge in Minnesota that ran over the Mississippi River in
August 2007, which plunged dozens of cars and their occupants into the river,
killed 13 people, and caused traffic problems that will continue for years to
come.
Two years earlier, in August 2005, the levees and floodwalls protecting the
city of New Orleans failed at multiple points during Hurricane Katrina,
flooding much of the city. The official death toll in New Orleans from the
hurricane and flooding was more than 1,300 people, and property damage was in
the tens of billions of dollars.
The deficiencies are not limited to bridges and levees, and disasters are not
always necessary to call attention to the deteriorating state of the U.S.
public works infrastructure. The condition of the pavement on highways and
roads throughout the country is a case in point.
Statistics from the Federal Highway Administration indicate that the
percentage of total vehicle miles traveled (VMT) on pavements with acceptable
ride quality has decreased over the past several years. The overall
deterioration adversely impacts travel in many ways, including increased wear
and tear on vehicle suspensions and tires; delays associated with vehicles
slowing to avoid potholes or other road damage; crashes caused by drivers
losing control of their vehicles; and reductions in fuel economy.
The solution to many of these problems lies in the construction materials and
other technologies used to build and maintain the bridges, roads, and other
public works. As of the writing of this report (i.e., November 2007), the
cause of the Minneapolis bridge collapse is still unknown, although there is
belief that corrosion may have played a role, as it did in the 1967 collapse
of the Silver Bridge over the Ohio River between Ohio and West Virginia, which
killed 46 people.
An investigation found that that the Silver Bridge disaster resulted from
stress corrosion and corrosion fatigue in the carbon steel of which the Silver
Bridge was constructed. The investigators also claimed that the conditions
that caused the collapse could not have been detected in advance unless the
bridge had been taken apart and tested. This finding underlines the importance
of material selection in ensuring the longevity and safety of public works
projects, as well as the importance of nondestructive testing technologies to
accurately monitor structural integrity on an ongoing basis.
The debate over funding the cost of repairing and upgrading America's
infrastructure, which has become more public in the aftermath of the
Minneapolis disaster, has highlighted another fact: The financial resources to
pay for the needed infrastructure repairs and upgrades, which according to
some estimates could ultimately total more than a trillion dollars, are
presently unavailable.
In particular, the Federal Highway Fund, which is supposed to finance the
lion's share of road and safety projects, is expected to have a negative
balance by 2010 or 2011. Proposals to finance the cost of bridge repairs by
increasing the federal gasoline tax have been met with significant political
opposition. As a result of these financial pressures, cost effectiveness
should be added to long service life and safety as key criteria for choosing
appropriate construction materials and technologies.
SCOPE OF STUDY
This report contains:
- Descriptions of various advanced materials and technologies for public
works including metals and alloys, superior performing asphalt pavements, high
performance concrete, fiber-reinforced polymer composites, geopolymers,
geosynthetics, smart materials and advanced structural subassemblies.
- The current market status of advanced materials and technologies for the
public works industry, with trends and forecasts for growth over the next 5
years
- Discussion of new technologies and a thorough patent analysis
- Analysis of the advanced materials and technologies for public works in
the U.S., both from a market and application perspective
- Profiles of the major developers and manufacturers of advanced
infrastructure materials and technologies
METHODOLOGY AND INFORMATION SOURCES
The findings and conclusions of this report are based on information gathered
from a wide range of sources, including infrastructure operators, vendors, and
engineering and consulting firms. Interview data were combined with
information gathered through an extensive review of secondary sources such as
trade publications, trade associations, company literature, and on-line
databases to produce the projections contained in this report.
The base-year for analysis and projection is 2006. With 2006 as a baseline,
market projections were developed for period ranging from 2007 to 2012. These
projections are based on a consensus among the primary contacts combined with
our understanding of the key market drivers and their impact from a historical
and analytical perspective.
The methodologies and assumptions used to develop the market projections in
this report are discussed at length under the various types of airport
technology addressed. The report carefully documents data sources and
assumptions. Thus, readers can see how the market estimates were developed and
can test the impact on the final numbers of changing assumptions (e.g., price).
TABLE OF CONTENTS
Table of Contents
- Advanced Materials and Technologies for Public Works Infrastructure
Projects
- Chapter 1 - SUMMARY
- SUMMARY TABLE: US PUBLIC WORKS INFRASTRUCTURE MARKET FOR ADVANCED
MATERIALS AND SUBASSEMBLIES, THROUGH 2012 ($ MILLIONS)
- SUMMARY FIGURE: U.S. PUBLIC WORKS INFRASTRUCTURE MARKET FOR ADVANCED
BUILDING MATERIALS AND SUBASSEMBLIES BY MAJOR END-USER SEGMENT, 2006-2012 (%)
- Chapter 2 - OVERVIEW
- DEFINITIONS
- PUBLIC WORKS INFRASTRUCTURE
- ADVANCED MATERIALS AND TECHNOLOGIES
- U.S. PUBLIC INFRASTRUCTURE INVESTMENTS
- TABLE 1 ANNUAL CAPITAL COSTS OF U.S. PUBLIC WORKS INFRASTRUCTURE,
THROUGH 2012 ($ MILLIONS)
- FIGURE 1 PUBLIC WORKS INFASTRUCTURE COMPONENTS SHARES OF TOTAL CAPITAL
EXPENDITURES, 2006-2012 (%)
- FIGURE 1 (CONTINUED)
- ADVANCED INFRASTRUCTURE MATERIALS AND SUBASSEMBLIES
- TABLE 2 U.S. MARKET FOR ADVANCED INFRASTRUCTURE MATERIALS AND
SUBASSEMBLIES, THROUGH 2012 ($ MILLIONS)
- FIGURE 2 ADVANCED INFRASTRUCTURE MATERIALS AND SUBASSEMBLIES MARKET
SHARES, 2006-2012 (%)
- FIGURE 2 (CONTINUED)
- Chapter 3 - U.S. PUBLIC WORKS INFRASTRUCTURE
- INFRASTRUCTURE CONDITIONS AND TRENDS
- FIGURE 3 U.S. HIGHWAY OWNERSHIP SHARES, 2000 VERSUS 2004 (% OF TOTAL
MILEAGE)
- TABLE 3 U.S. HIGHWAY MILEAGE BY OWNERSHIP, THROUGH 2005 (THOUSAND
MILES/% OF TOTAL MILES)
- Current Status and Condition
- TABLE 4 FHWA PAVEMENT SURFACE QUALITY CRITERIA
- TABLE 5 CONDITION OF U.S. ROADS AND HIGHWAYS, 2004 (THOUSAND MILES
- FIGURE 4 CONDITION OF U.S. ROADS AND HIGHWAYS, 2004 (%)
- Construction and Maintenance Expenditures
- TABLE 6 U.S. HIGHWAY EXPENDITURES, THROUGH 2005 ($ BILLIONS)
- FIGURE 5 HIGHWAY CAPITAL EXPENDITURES, 2006-2012 ($ BILLIONS)
- Sources of Financing
- Federal Government
- Federal Government (Continued)
- TABLE 7 CONGRESSIONAL BUDGET OFFICE ESTIMATE OF FUNDS AVAILABLE FOR
OBLIGATION FROM THE HIGHWAY TRUST FUND, 2006-2009 ($ BILLIONS)
- State and Local Governments
- FIGURE 6 STATE AND LOCAL REVENUES FOR HIGHWAYS, 2005 (%)
- TABLE 8 TOLL ROAD PRIVATIZATIONS
- RAILWAY AND COMMUTER RAIL LINES
- FIGURE 7 OWNERSHIP OF U.S. RAILWAY TRACKS, 2006 (% OF TOTAL TRACK
MILEAGE)
- Current Status and Condition
- FIGURE 8 TRENDS IN TRACK RELATED RAILROAD INCIDENTS/ACCIDENTS, 1995-2005
(NUMBER AND RATE PER MILLION TRAIN MILES)
- FIGURE 8 (CONTINUED)
- Capital Expenditures and Sources of Funds
- TABLE 9 PROJECTED TOTAL EXPENDITURES ON RAILWAY TRACK NEW CONSTRUCTION
AND REHABILITATION, THROUGH 2012($ MILLIONS)
- FIGURE 9 AMTRAK INFRASTRUCTURE GRANTS, FY 2004-2007 ($ MILLIONS)
- FIGURE 10 AMTRAK USES OF CAPITAL FUNDS (%)
- TABLE 10 PRIIA ANNUAL CAPITAL GRANTS, FY 2007-2012 ($ BILLIONS)
- TABLE 11 PROJECTED AMTRAK EXPENDITURES ON TRACK CONSTRUCTION AND
REHABILITATION, THROUGH 2012 ($ MILLIONS)
- Other Government Agencies
- FIGURE 11 COMMUTER, HEAVY, AND LIGHT RAIL CAPITAL EXPENDITURES, FY
2001-FY 2005 ($ BILLIONS)
- FIGURE 12 EXPENDTURE ON COMMUTER, HEAVY, AND LIGHT RAIL TRACK AND
SYSTEMS, FY 2005 (%)
- TABLE 12 FUTURE COMMUTER, HEAVY AND LIGHT RAIL LINES (MILES)
- TABLE 13 PROJECTED EXPENDITURES ON NEW PUBLIC TRANSIT RAIL TRACKS,
THROUGH 2012 ($ BILLIONS)
- Privately Owned Railroads
- FIGURE 13 TRENDS IN U.S. PRIVATE RAILROADS' ANNUAL INFRASTRUCTURE
EXPENDITURES, 1997
- TABLE 14 PROJECTED PRIVATE RAILROADS' TRACK EXPENDITURES, THROUGH 2012
($ MILLIONS)
- BRIDGES
- Highway Bridges
- Current Status and Condition
- FIGURE 14 CURRENT CONDITION OF U.S. HIGHWAY BRIDGES, 2007 (%)
- Construction and Repair Expenditures and Sources of Funding
- TABLE 15 PROJECTED EXPENDITURES ON HIGHWAY BRIDGE REPLACEMENT AND
REHABILITATION BY ALL LEVELS OF GOVERNMENT, THROUGH 2012 ($ BILLIONS)
- TABLE 16 PROJECTED EXPENDITURES ON HIGHWAY BRIDGE REPLACEMENT AND
REHABILITATION BY ALL LEVELS OF GOVERNMENT, THROUGH 2012 ($ BILLIONS)
- FIGURE 15 FEDERAL HIGHWAY BRIDGE PROGRAM BUDGET AUTHORIZATIONS, FY
1997-FY 2006 ($ BILLIONS)
- TABLE 17 HIGHWAY BRIDGE CONSTRUCTION AND REPAIR EXPENDITURES AUTHORIZED
UNDER SAFETEA-LU, 2005-2009 ($ BILLIONS)
- TABLE 18 PROJECTED FEDERALLY FINANCED EXPENDITURES ON BRIDGE REPLACEMENT
AND REHABILITATION, THROUGH 2012 ($ BILLIONS)
- FIGURE 16 U.S. RAILWAY BRIDGES BY TYPE OF OWNER, 2006 (%)
- Current Status and Condition
- Construction and Repair Expenditures
- TABLE 19 PROJECTED TOTAL EXPENDITURES ON RAILWAY BRIDGE CONSTRUCTION,
REPLACEMENT AND REHABILITATION, THROUGH 2012 ($ MILLIONS)
- TABLE 20 MAJOR BRIDGE PROJECTS PLANNED BY AMTRAK, 2006-2012
- FIGURE 17 PROJECTED AMTRAK SPENDING ON BRIDGE REPLACEMENT AND
REHABILITATION, 2006-2012 ($ MILLIONS)
- FIGURE 17 (CONTINUED)
- State and Local Governments
- TABLE 21 PROJECTED STATE AND LOCAL TRANSIT BRIDGE EXPENDITURES, THROUGH
2012 ($ MILLIONS)
- Private Railroads
- TABLE 22 PROJECTED EXPENDITURES ON BRIDGE REPLACEMENT AND REHABILITATION
BY PRIVATE RAILROADS, THROUGH 2012 ($ MILLIONS)
- FIGURE 18 U.S. RAILWAY TUNNELS BY OWNER (%)
- Current Status and Condition
- Construction and Repair Expenditures
- Construction ý (Continued)
- TABLE 23 TYPICAL TUNNEL REHABILITATION PROJECT COSTS
- TABLE 24 RAIL TUNNEL CONSTRUCTION, IMPROVEMENT, AND REHABILITATION
COSTS, THROUGH 2012* ($ MILLIONS)
- Highway Tunnels
- Current Status and Condition
- Construction and Repair Expenditures
- TABLE 25 HIGHWAY TUNNEL CONSTRUCTION, IMPROVEMENT, AND REHABILITATION
COSTS, THROUGH 2012 ($ MILLIONS)
- AIRPORTS
- Ownership
- Ownership (Continued)
- Current Status and Condition
- Runways
- TABLE 26 NEW RUNWAY PROJECTS IN PROGRESS OR PLANNED IN THE U.S.,
2006-2012
- TABLE 26 (CONTINUED)
- FIGURE 19 CONDITION OF RUNWAYS AT U.S. COMMERCIAL SERVICE AIRPORTS
2000-2004 (% OF TOTAL RUNWAYS)
- FIGURE 19 (CONTINUED)
- FIGURE 20 PROJECTED NUMBER OF DOMESTIC PASSENGERS USING U.S. AIRPORTS,
2006-2012 (MILLIONS)
- TABLE 27 NEW AIRPORT TERMINAL PROJECTS IN PROGRESS OR PLANNED IN THE
U.S., 2006-2012
- TABLE 27 (CONTINUED)
- Construction and Repair Expenditures
- FIGURE 21 ESTIMATED AIRPORT TERMINAL AND RUNWAY CONSTRUCTION AND
REHABILITATION EXPENDITURES, 2006-2012 ($ BILLIONS)
- Sources of Financing
- Airport Improvement Program
- State Grants
- Individual Airport Finances
- DAMS
- Current Status and Condition
- Construction and Repair Expenditures
- TABLE 28 TOTAL PUBLIC SPENDING ON DAM SAFETY, REHABILITATION, AND
CONSTRUCTION, THROUGH
- Sources of Financing
- Federal Dam Safety Legislation Moves Forward
- INLAND WATERWAYS
- Ownership
- Current Status and Condition
- Construction and Repair Expenditures
- TABLE 29 TOTAL PUBLIC SPENDING ON INLAND WATERWAY REHABILITATION AND
CONSTRUCTION, THROUGH 2012 ($ MILLIONS)
- Sources of Financing
- LEVEES AND FLOODWALLS
- Ownership
- Current Status and Condition
- FIGURE 22 NUMBERS OF AT-RISK LEVEES BY STATE, 2007 (NUMBER OF LEVEES)
- Construction and Repair Expenditures
- TABLE 30 PUBLIC SPENDING ON LEVEE REHABILITATION AND CONSTRUCTION IN THE
AFTERMATH OF HURRICANE KATRINA, THROUGH 2012* ($ MILLIONS)
- PORTS
- Ownership
- Current Status and Condition
- FIGURE 23 TRENDS IN CARGO HANDLED BY US COASTAL AND INLAND PORTS,
2001-2006 (MILLION SHORT TONS)
- Construction and Repair Expenditures
- FIGURE 24 U.S. PUBLIC PORTS' INFRASTRUCTURE INVESTMENTS, 2001-2005 ($
MILLIONS)
- FIGURE 25 PROJECTED SOURCES OF FINANCING FOR PUBLIC PORT CAPITAL
INVESTMENTS, 2006-2010 (% OF TOTAL FUNDS)
- Chapter 4 - MARKET FOR ADVANCED INFRASTRUCTURE CONSTRUCTION MATERIALS AND
SUBASSEMBLIES
- MATERIALS
- TABLE 31 MARKET FOR ADVANCED METALS AND ALLOYS IN CIVIL INFRASTURCTURE
PROJECTS, THROUGH 2012 ($ MILLIONS)
- High-Performance Steels
- Properties versus Competing Materials
- Applications
- Commercial Status and Market
- TABLE 32 ANNUAL SALES OF HIGH-PERFORMANCE STEEL FOR BRIDGE APPLICATIONS,
THROUGH 2012 (TONS/$ MILLION)
- MMFX Steel
- Properties versus Competing Materials
- Applications
- Commercial Status and Market
- Commercial Status ý (Continued)
- Commercial ý (Continued)
- TABLE 33 ANNUAL SALES OF MMFX REBAR FOR INFRASTUCTURE APPLICATIONS,
THROUGH 2012 ($ MILLIONS)
- SUPERIOR PERFORMING ASPHALT PAVEMENTS (SUPERPAVE)
- Properties versus Competing Materials
- Applications
- Commercial Status and Markets
- TABLE 34 ANNUAL CONSUMPTION OF SUPERPAVE HOT ASPHALT MIX, THROUGH 2012
(MILLION TONS/$ MILLIONS)
- HIGH-PERFORMANCE CONCRETE
- Properties versus Competing Materials
- TABLE 35 HCP BENEFITS VERSUS CONVENTIONAL CONCRETE
- TABLE 36 TYPES OF HPC DEVELOPED UNDER FHWA STRATEGIC HIGHWAY RESEARCH
PROGRAM
- Applications
- Commercial Status and Market
- TABLE 37 TOTAL CEMENT CONSUMPTION IN BRIDGE CONSTRUCTION AND
REHABILITATION, THROUGH 2012 ($ BILLION/MILLION TONS)
- TABLE 38 TOTAL HPC CONSUMPTION IN BRIDGE CONSTRUCTION AND
REHABILITATION, HROUGH 2012 ($ BILLION/ MILLION TONS)
- GEOPOLYMERS
- Properties versus Competing Materials
- Applications
- Commercial Status and Markets
- TABLE 39 TOTAL U.S. GEOPOLYMER CONSUMPTION IN CONCRETE INFRASTLURCTURE
PROTECTIVE COATINGS, THROUGH 2012 ($ MILLIONS)
- FIBER-REINFORCED POLYMER COMPOSITES
- Properties versus Competing Materials
- Properties versus ý (Continued)
- Properties versus ý (Continued)
- Properties versus ý (Continued)
- Applications
- Reinforcing Bars
- Bridge Decks
- Pilings
- Railroad Ties
- FIGURE 26 U.S. RAILWAY TIE CONSUMPTION BY TYPE OF MATERIAL, 2006 (% OF
TOTAL RAILWAY TIES)
- Seismic Retrofit
- Roadside Structures
- Other FRP Applications
- Commercial Status and Markets
- TABLE 40 INFRASTRUCTURE MARKETS FOR FIBER REINFORCED POLYMER, THROUGH
2012 ($ MILLIONS)
- FIGURE 27 FIBER REINFORCED POLYMER INFRASTRUCTURE MARKET SEGMENTS,
2006-2012 (%)
- TABLE 41 COMMERCIAL PRODUCERS OF FRP REINFORCING BAR
- TABLE 42 U.S. INFRASTRUCTURE MARKET FOR FRP REBAR, THROUGH 2007 ($
MILLIONS)
- FIGURE 28 TRENDS IN NUMBER OF NEW FRP BRIDGE DECKS INSTALLED IN THE
U.S., 1996-2006 (NUMBER OF DECKS)
- FRP Bridge Decks (Continued)
- TABLE 43 COMPANIES INVOLVED IN THE PRODUCTION OF FRP BRIDGE DECKS
- TABLE 44 PROJECTED MARKET FOR FRP BRIDGE DECKS, THROUGH 2012 ($ MILLIONS)
- FRP Marine Pilings
- TABLE 45 PROJECTED MARKET FOR FRP MARINE PILINGS, THROUGH 2012 ($
MILLIONS)
- FRP Railroad Ties
- FRP ý (Continued)
- TABLE 46 PROJECTED MARKET FOR FRP RAIROAD TIES, THROUGH 2012 (NUMBER OF
TIES/$ MILLION)
- TABLE 47 PROJECTED MARKET FOR FRP SEISMIC REINFORCEMENT MATERIALS,
THROUGH 2012 ($ MILLIONS)
- Roadside Structures
- TABLE 48 PROJECTED MARKET FOR FRP ROADSIDE STRLUCTURES, THROUGH 2012 ($
MILLIONS)
- Miscellaneous Infrastructure Applications
- TABLE 49 PROJECTED MARKET FOR FRP MATERIALS IN OTHER INFRASTRCTURE
STRENGTHENING AND REPAIR APPLICATIONS, THROUGH 2012 ($ MILLIONS)
- GEOSYNTHETICS
- Properties versus Competing Systems
- Applications
- Road Structures, Runways, and Railway Beds
- Levees
- Dams
- Commercial Status and Markets
- TABLE 50 INFRASTRUCTURE-RELATED MARKET FOR GEOTEXTILES AND OTHER
GEOSYNTHETIC MATERIALS, THROUGH 2012
- SMART MATERIALS
- Properties
- Optical Fibers
- Piezoelectric Materials
- Smart-Tagged Composites
- Applications
- Commercial Status and Markets
- TABLE 51 PROJECTED INFRASTRUCTURE MARKET FOR SMART MATERIALS, THROUGH
2012 ($ MILLIONS)
- SUB-ASSEMBLIES
- PREFABRICATED BRIDGE ELEMENTS AND STURCTURES
- Properties
- Applications
- Commercial Status and Markets
- TABLE 52 PROJECTED MARKET FOR PREFABRICATED BRIDGE ELEMENTS AND
STRUCTURES, THROUGH 2012 ($ MILLIONS)
- SEISMIC ISOLATION BEARINGS
- Properties
- Friction Pendulum Bearings
- Lead Core Rubber Bearings
- Slider Bearings
- Fluid Dampers
- Applications
- Commercial Status and Markets
- TABLE 53 SUPPLIERS OF SEISMIC ISOLATION BEARINGS
- TABLE 54 PROJECTED MARKET FOR SEISMIC ISOLATION BEARINGS, THROUGH 2012
($ MILLIONS)
- Chapter 5 - APPENDIX I: COMPANY PROFILES
- METALS AND ALLOYS
- EVRAZ OREGON STEEL MILLS, INC.
- MITTAL STEEL USA INC.
- MMFX STEEL CORP. OF AMERICA
- HIGH-PERFORMANCE CEMENTS
- FIBER-REINFORCED POLYMER COMPOSITES
- BEDFORD REINFORCED PLASTICS, INC.
- COMPOSITE REBAR TECHNOLOGIES
- CONSERV EPOXY LLC
- CREATIVE PULTRUSIONS, INC.
- FIBRWRAP CONSTRUCTION, INC.
- FYFE CO. LLC
- HARD CORE COMPOSITES LLC
- HEXCEL SCHWEBEL CORP.
- HUGHES BROTHERS, INC.
- INFRASTRUCTURE COMPOSITES INTERNATIONAL
- JEROL INDUSTRI AB
- KANSAS STRUCTURAL COMPOSITES, INC.
- LANCASTER COMPOSITE, INC.
- LEE COMPOSITES, INC.
- MARTIN MARIETTA COMPOSITES
- POLYWOOD INC.
- POWERTRUSION INTERNATIONAL INC.
- PULTRALL, INC.
- QUAKEWRAP, INC.
- SEAWARD
- SIKA CORP.
- STRONGWELL CORP.
- SUDAGLASS FIBER TECHNOLOGY, INC.
- TIE TEK LLC
- TILLCO COMPANY
- PREFABRICATED BRIDGE ELEMENTS AND SYSTEMS
- ACROW CORP.
- CONTECH BRIDGE SOLUTIONS INC.
- OHIO BRIDGE
- SEISMIC ISOLATION BEARINGS
- EARTHQUAKE PROTECTION SYSTEMS, INC.
- DYNAMIC ISOLATION SYSTEMS, INC.
- R.J. WATSON BRIDGE & STRUCTURAL ENGINEERED SYSTEMS
- SEISMIC ENERGY PRODUCTS, LP
- GEOSYNTHETICS
- AGRU AMERICA, INC.
- GUNDLESLT ENVIRONMENTAL, INC.
- PROPEX, INC.
- STRATA SYSTEMS, INC.
- TENCATE GEOSYNTHETICS NORTH AMERICA
- US FABRICS, INC.
- Chapter 6 - APPENDIX II: U.S. PATENT ANALYSIS
- INTRODUCTION
- FIGURE 29 PATENT SHARES BY TYPE OF MATERIAL (% OF ALL PATENTS ISSUED
THROUGH DECEMBER 15, 2007
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