Manual For Design, Construction, And Maintenance Of .

captured 12/13/13Publication No. FHWA-IF-12-027February 2012US DEPARTMENT OF TRANSPORTATIONFEDERAL HIGHWAY ADMINISTRATIONMANUAL FOR DESIGN, CONSTRUCTION, ANDMAINTENANCE OF ORTHOTROPIC STEELDECK BRIDGES

NoticeThis document is disseminated under the sponsorship of the U.S. Department of Transportationin the interest of information exchange. The U.S. Government assumes no liability for the useof the information contained in this document. This report does not constitute a standard,specification, or regulation.The U.S. Government does not endorse products or manufacturers. Trademarks ormanufacturers’ names appear in this report only because they are considered essential to theobjective of the document.Quality Assurance StatementThe Federal Highway Administration (FHWA) provides high-quality information to serveGovernment, industry, and the public in a manner that promotes public understanding. Standardsand policies are used to ensure and maximize the quality, objectivity, utility, and integrity of itsinformation. FHWA periodically reviews quality issues and adjusts its programs and processes toensure continuous quality improvement.

TECHNICAL DOCUMENTATION PAGE1. Report No.2. Government Accession No.FHWA-IF-12-0274. Title and SubtitleManual for Design, Construction, and Maintenance of Orthotropic SteelDeck Bridges3. Recipient’s Catalog No.5. Report Date6. Performing Organization Code7. Author(s)8. Performing Organization Report No.Robert Connor, John Fisher, Walter Gatti, Vellore Gopalaratnam, BrianKozy, Brian Leshko, David L. McQuaid, Ronald Medlock, Dennis Mertz,Thomas Murphy, Duncan Paterson, Ove Sorensen, John Yadlosky9. Performing Organization Name and AddressHDR Engineering Inc.,10. Work Unit No. (TRAIS)11. Contract or Grant No.DTFH61-07-D-0000411 Stanwix Street, Pittsburgh, PA 1522212. Sponsoring Agency Name and AddressOffice of Bridge TechnologyFederal Highway Administration13. Type of Report and Period Covered1200 New Jersey Avenue, S.E. Washington, D.C. 2059014. Sponsoring Agency Code15. Supplementary NotesThe FHWA Contracting Officer’s Technical Representative (COTR) was Raj Ailaney.Front cover photograph is a fabricated deck segment for the new San Francisco Oakland Bay Bridge Self AnchoredSuspension Span. Reprinted with permission from Metropolitan Transportation Commission and photographer TomPaiva (www.tompaiva.com).16. AbstractThis Manual covers the relevant issues related to orthotropic steel deck bridge engineering, including analysis, design,detailing, fabrication, testing, inspection, evaluation, and repair. It includes a discussion of some the variousapplications of orthotropic bridge construction to provide background with case study examples. It also provides basiccriteria for the establishment of a cost-effective and serviceable orthotropic bridge cross section with detailinggeometry that has been used on recent projects worldwide. The manual covers both the relevant information necessaryfor the engineering analysis of the orthotropic steel bridge and the requirements for complete design of orthotropic steelbridge superstructures. Additionally, design details such as materials, corrosion protection, minimum proportions, andconnection geometry are addressed as well as basic fabrication, welding, and erection procedures. Portions of themanual also cover methods for maintaining and evaluating orthotropic bridges, including inspection and load rating.Wearing surfaces are also covered in depth. The culmination of all the information is demonstrated in two designexamples.17. Key WordsSteel BridgesBridge DecksOrthotropic Steel DeckOrthotropic Bridge Design19. Security Classif. (of this report)UnclassifiedForm DOT F 1700.7 (8-72)18. Distribution StatementNo restrictions. This document is availableto the public through NTIS:National Technical Information Service5301 Shawnee RoadAlexandria, VA 2231220. Security Classif. (of this page)21. No. of Pages22. PriceUnclassified262Reproduction of completed page authorized

SI* (MODERN METRIC) CONVERSION FACTORSAPPROXIMATE CONVERSIONS TO SI UNITSSymbolWhen You KnowinftydmiinchesfeetyardsmilesMultiply ByLENGTH25.40.3050.9141.61To quare millimeterssquare meterssquare metershectaressquare kilometersmm2mm2ha2kmAREA2in2ftyd2ac2misquare inchessquare feetsquare yardacressquare miles645.20.0930.8360.4052.59fl ozgalft33ydfluid ouncesgallonscubic feetcubic yardsozlbTouncespoundsshort tons (2000 in2poundforcepoundforce per square inch2VOLUME29.57milliliters3.785liters0.028cubic meters0.765cubic meters3NOTE: volumes greater than 1000 L shall be shown in mmLLm33mMASS28.350.4540.907gramskilogramsmegagrams (or "metric ton")gkgMg (or "t")TEMPERATURE (exact degrees)F5 (F-32)/9or N10.763.426FORCE and PRESSURE or STRESS4.456.89newtonskilopascalsNkPaAPPROXIMATE CONVERSIONS FROM SI UNITSSymbolWhen You KnowMultiply 2m2mha2kmsquare millimeterssquare meterssquare metershectaressquare kilometersmLLm33mmillilitersliterscubic meterscubic metersgkgMg (or "t")gramskilogramsmegagrams (or "metric ton")oCelsius0.0393.281.090.621To FindSymbolinchesfeetyardsmilesinftydmisquare inchessquare feetsquare yardsacressquare milesin22ft2ydac2mifluid ouncesgallonscubic feetcubic yardsfl ozgalft33ydouncespoundsshort tons (2000 .26435.3141.307MASS0.0352.2021.103TEMPERATURE (exact degrees)C1.8C 9290.2919FORCE and PRESSURE or STRESS0.2250.145poundforcepoundforce per square inchlbf2lbf/in*SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380.(Revised March 2003)ii

TABLE OF CONTENTSFOREWORD. 1ACKNOWLEDGEMENTS . 2CHAPTER 1 – INTRODUCTION . 41.1 Introduction to Orthotropic Bridge Decks . 41.2 Organization of the Manual . 9CHAPTER 2 - BRIDGE APPLICATIONS . 102.1 General Background . 102.2 Plate Girder Bridges . 112.3 Box Girder Bridges . 122.4 Suspended Span Bridges . 142.5 Bridge Redecking. 152.6 Movable Bridges . 16CHAPTER 3 - TYPICAL BRIDGE SECTIONS . 183.1 General Layout. 183.2 Orthotropic Panel Details . 193.2.1 Open Rib Systems . 203.2.2 Closed Rib Systems . 213.2.3 Rib Proportioning. 21CHAPTER 4 – STRUCTURAL BEHAVIOR AND ANALYSIS . 244.1 Evolving Practices . 244.2 Behavioral Mechanisms . 304.2.1 Local Deck Plate Deformation – System 1 . 314.2.2 Panel Deformation – System 2 . 324.2.3 Rib Longitudinal Flexure – System 3 . 344.2.4 Floorbeam In-Plane Flexure – System 4 . 354.2.5 Floorbeam Distortion – System 5 . 364.2.6 Rib Distortion – System 6 . 404.2.7 Global – System 7 . 414.3 Effective Width . 414.4 Load Paths and Load Distribution . 444.5 Fatigue Performance of Steel CONNECTION Details . 454.5.1 Rib-to-Deck Plate (RD) Weld. 45iii

4.5.2 Rib and Deck Splices . 484.5.3 Rib-to-Floorbeam (RF) . 504.5.4 Rib-to-deck at Floorbeam Joint (RDF) . 534.6 Refined Analysis for Fatigue Assessment . 534.6.1 Influence Surface Analysis . 554.6.2 Evaluation of Stresses . 584.7 Composite Behavior with Deck Surfacing . 624.8 Stability . 624.8.1 Local Buckling . 634.8.2 Panel Buckling . 654.8.3 Residual Stresses . 674.8.4 Imperfections . 674.8.5 Second Order Effects . 68CHAPTER 5 - DESIGN . 705.1 General Design approach . 705.1.1 Design Level . 705.1.2 Design Life. 725.2 General Design approach . 725.2.1 Strength Limit State . 725.2.2 Service Limit State. 735.2.3 Fatigue Limit State. 735.2.4 Constructability . 745.3 Load Factors and Combinations . 745.4 Permanent Loads . 755.5 Live Loads . 765.5.1 Design Truck or Tandem Load . 765.5.1.1 Application. 765.5.1.2 Orthotropic Steel Deck Refined Design Truck . 765.5.1.3 Fatigue Application. 775.5.2 Multiple Presence Factors (MPF) . 785.5.3 Dynamic Load Allowance (IM) . 785.5.4 Site Specific Live Load Models . 785.6 Analysis. 795.7 Fatigue Resistance . 835.7.1 Analytical Resistance Models . 845.7.1.1 Nominal Stress S-N Curve Approach for Level 2 Design . 84iv

5.7.1.2 Local Structural Stress Approach for Level 3 Design . 865.7.2 Rib-to-Deck (RD) Weld. 895.7.3 Rib Splice . 905.7.4 Deck Plate Splice . 905.7.4.1 Transverse Splice . 915.7.4.2 Longitudinal Splice . 915.7.4.3 Bolted Splice . 915.7.5 Rib-to-floorbeam (RF) . 925.7.5.1 Cut-out Detail. 925.7.5.2 Weld All Around Detail . 955.7.6 Rib-to-deck at Floorbeam (RDF) . 975.7.7 Summary . 985.8 Fracture Considerations . 1015.9 Redecking Considerations . 101CHAPTER 6 - DETAILING . 1026.1 Materials . 1026.2 Corrosion Protection . 1036.3 General Proportions . 1046.4 Rib-to-Deck Plate (RD) Weld. 1056.5 Rib-to-Floorbeam (RF) Connection . 1066.6 Rib-to-Deck at the Floorbeam (RDF) . 1106.7 Splices and Deck Joints . 1106.8 Redecking Details . 1146.9 Barrier Details . 117CHAPTER 7 - CONSTRUCTION . 1207.1 Fabrication Documents . 1207.1.1 Fabrication Specifications . 1207.1.2 Certifications and Qualifications . 1217.1.3 Fabrication Plan . 1217.1.4 Drawings . 1217.2 Fabrication Sequence . 1227.3 Fabrication Process . 1247.3.1 Distortion Control . 1247.3.2 Tack Welds . 1277.3.3 Splices . 1277.3.4 Internal Bulkheads . 128v

7.4 Welding . 1287.4.1 Rib-to-Floorbeam (RF) . 1297.4.2 Rib-to-Deck Plate (RD) . 1297.4.2.1 RD Welding Procedure . 1307.4.2.2 Procedure Development . 1317.4.2.3 Proficiency Testing . 1337.4.2.4 Pre-production Weld Trials. 1347.4.2.5 Fit-Up . 1347.4.2.6 Tack Welding .

This Manual covers the relevant issues related to orthotropic steel deck bridge engineering, including analysis, design, detailing, fabrication, testing, inspection, evaluation, and repair. It includes a discussion of some the various applications of orthotropic bridge construction to provide background with case study examples.