Publication No. FHWA-IF-12-027 February 2012 US DEPARTMENT OF TRANSPORTATION FEDERAL HIGHWAY ADMINISTRATION MANUAL FOR DESIGN, CONSTRUCTION, AND MAINTENANCE OF ORTHOTROPIC STEEL DECK BRIDGES Notice This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for the use of 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 or manufacturers’ names appear in this report only because they are considered essential to the objective of the document. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. TECHNICAL DOCUMENTATION PAGE 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FHWA-IF-12-027 4. Title and Subtitle 5. Report Date Manual for Design, Construction, and Maintenance of Orthotropic Steel Deck Bridges 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Robert Connor, John Fisher, Walter Gatti, Vellore Gopalaratnam, Brian Kozy, Brian Leshko, David L. McQuaid, Ronald Medlock, Dennis Mertz, Thomas Murphy, Duncan Paterson, Ove Sorensen, John Yadlosky 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) HDR Engineering Inc., 11. Contract or Grant No. 11 Stanwix Street, Pittsburgh, PA 15222 DTFH61-07-D-00004 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Office of Bridge Technology Federal Highway Administration 14. Sponsoring Agency Code 1200 New Jersey Avenue, S.E. Washington, D.C. 20590 15. Supplementary Notes The 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 Anchored Suspension Span. Reprinted with permission from Metropolitan Transportation Commission and photographer Tom Paiva (www.tompaiva.com). 16. Abstract 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. It also provides basic criteria for the establishment of a cost-effective and serviceable orthotropic bridge cross section with detailing geometry that has been used on recent projects worldwide. The manual covers both the relevant information necessary for the engineering analysis of the orthotropic steel bridge and the requirements for complete design of orthotropic steel bridge superstructures. Additionally, design details such as materials, corrosion protection, minimum proportions, and connection geometry are addressed as well as basic fabrication, welding, and erection procedures. Portions of the manual 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 design examples. 17. Key Words 18. Distribution Statement Steel Bridges No restrictions. This document is available Bridge Decks to the public through NTIS: Orthotropic Steel Deck National Technical Information Service Orthotropic Bridge Design 5301 Shawnee Road Alexandria, VA 22312 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 262 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized SI* (MODERN METRIC) CONVERSION FACTORS APPROXIMATE CONVERSIONS TO SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2000 lb) 0.907 megagrams (or "metric ton") Mg (or "t") TEMPERATURE (exact degrees) oF Fahrenheit 5 (F-32)/9 Celsius oC or (F-32)/1.8 ILLUMINATION fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS lbf poundforce 4.45 newtons N lbf/in2 poundforce per square inch 6.89 kilopascals kPa APPROXIMATE CONVERSIONS FROM SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or "t") megagrams (or "metric ton") 1.103 short tons (2000 lb) T TEMPERATURE (exact degrees) oC Celsius 1.8C+32 Fahrenheit oF ILLUMINATION lx lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-Lamberts fl FORCE and PRESSURE or STRESS N newtons 0.225 poundforce lbf kPa kilopascals 0.145 poundforce per square inch lbf/in2 *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 CONTENTS FOREWORD................................................................................................................................. 1 ACKNOWLEDGEMENTS ......................................................................................................... 2 CHAPTER 1 – INTRODUCTION .............................................................................................. 4 1.1 Introduction to Orthotropic Bridge Decks .......................................................................... 4 1.2 Organization of the Manual ................................................................................................ 9 CHAPTER 2 - BRIDGE APPLICATIONS .............................................................................. 10 2.1 General Background ......................................................................................................... 10 2.2 Plate Girder Bridges .......................................................................................................... 11 2.3 Box Girder Bridges ........................................................................................................... 12 2.4 Suspended Span Bridges ................................................................................................... 14 2.5 Bridge Redecking.............................................................................................................. 15 2.6 Movable Bridges ............................................................................................................... 16 CHAPTER 3 - TYPICAL BRIDGE SECTIONS ..................................................................... 18 3.1 General Layout.................................................................................................................. 18 3.2 Orthotropic Panel Details .................................................................................................. 19 3.2.1 Open Rib Systems .................................................................................................... 20 3.2.2 Closed Rib Systems ................................................................................................. 21 3.2.3 Rib Proportioning..................................................................................................... 21 CHAPTER 4 – STRUCTURAL BEHAVIOR AND ANALYSIS ........................................... 24 4.1 Evolving Practices ............................................................................................................ 24 4.2 Behavioral Mechanisms .................................................................................................... 30 4.2.1 Local Deck Plate Deformation – System 1 .............................................................. 31 4.2.2 Panel Deformation – System 2 ................................................................................ 32 4.2.3 Rib Longitudinal Flexure – System 3 ...................................................................... 34 4.2.4 Floorbeam In-Plane Flexure – System 4 .................................................................. 35 4.2.5 Floorbeam Distortion – System 5 ............................................................................ 36 4.2.6 Rib Distortion – System 6 ........................................................................................ 40 4.2.7 Global