DESIGN TASK PROTOCOL

Design Task Protocol No.:

DRSR - 001

Project:
Job No.:
Design Task Element:

I-91 over Deerfield River

60132040 / 62146
DF (D-06-044) Superstructure-Steel
Deck Design
Substructure

Bob Hajjar
Originator / 3/4/2009

Revision No.:

John Smith
Reviewer / 3/7/2009

Objective

The purpose of this task is to design the superstructure elements of the replacement
bridge which carries Interstate 91 (I-91) over the Deerfield River and Stillwater Road.
The project consists of replacing the existing 6-span Northbound and Southbound bridges
with new 5-span steel plate-girder bridges.
This work includes, but is not limited to:
o Superstructure design of steel plate girders, diaphragms, utility supports, splices,
bearing stiffeners, shear connectors, and the calculation of cambers and top of
form elevations.
o Deck Design selection of reinforcement and concrete deck thickness as well as
selection of additional reinforcement in deck overhangs.
o Substructure design of the abutment, reinforcement and geometry; calculation
of beam seat elevations at abutments and piers; pier wall design including
reinforcing in the wall and pile cap, selection of pipe piles at the piers, and design
of the cofferdam and tremie seal at the piers.

Prerequisites (Input)

Required Formats:
o All calculations and drawings will be in English units.
o Two independent sets of calculations will be performed for the design, with the
exception of the steel plate girder design, which will be designed using MerlinDash and independently verifying the input. All detailing work computed using
Merlin-Dash shall be verified by equivalent hand calculations.
o Computations should be performed in accordance with current Design Control
Procedures for the Preparation and Review of Calculations.

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o Contract Drawings should be produced in accordance with current Design Control

Procedures for the Preparation and Review of Drawings and MassDOT Bridge
Manual.
Design results from other disciplines: Alignment, Horizontal and Vertical Geometry and
construction phasing will be coordinated with the Civil Department of AECOM
Technical Services. Survey information also exists.
Existing test data or analyses: Existing borings.
Required test data: No additional test data is required.

Design

Design Criteria: All design is in accordance with the 5th Edition of AASHTO LRFD
Bridge Design Specifications 2010, the 1st Edition of AASHTO Guide Specifications for
LRFD Seismic Bridge Design 2009, and the Massachusetts Department of Transportation
(MassDOT) LRFD Bridge Manual (2009) Part I and II. All steel design shall be designed
by the Load and Resistance Factor Design Method (LRFD).

Client Specifications: See above.

Design Manuals:
o MassDOT Highway Division LRFD Bridge Manual (2009)

Design Codes and Standards:

o AASHTO LRFD Bridge Design Specifications 5th Edition 2010, AASHTO Guide
Specifications for LRFD Seismic Bridge Design 1st Edition 2009

Design Loads: This structure will be designed for AASHTO group loadings, including:
dead load, live load, wind, seismic, and all other loads as directed by the Codes and
Standards above, with minimum values as specified below:
o Dead Load
Soil
Concrete
Steel
Water
Pavement

120 pcf
150 pcf
490 pcf
62.4 pcf
150 pcf a 3 HMA wearing surface shall
be taken into account
250 plf (B.M. section 3.5.4.2)

Utility loads

o Live Load
Each bridge shall be designed for HL93 truck loading. Appropriate
distribution factors will be calculated by AASHTO and dynamic load
allowance shall be included. Two 12 lanes, one 10-0 shoulder, and one
8-0 shoulder will be carried over each bridge (D-06-044). Staged
construction need not be considered in the superstructure design as a
temporary bridge will be provided.
o Wind Load
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A wind load of 50 psf shall be applied horizontally and at right angles for
groups II and V. Groups III and VI loadings shall comprise the loads used
in group II and V reduced by 70%.

o Seismic Load
25 percent of tributary dead load is considered for seismic design of
substructure. Per Section 3.10.8 of AASHTO LRFD Bridge Design
Specifications 2010, 100 percent of the absolute value of the force effects
in one of the perpendicular directions will be combined with 30 percent of
the absolute value of the force effects in the second perpendicular
direction and vice versa.

Materials:
o Superstructure
o Concrete: 4000 psi, 585 HP Cement Concrete for deck,
o Reinforcement: AASHTO M31, GRADE 60 Stainless Steel
o Structural Steel: Uncoated weathering steel, AASHTO M270, Grade 50W
o High Strength Bolts:
All field connections shall be made with AASHTO M164 (A325)
o Anchor Rods: ASTM F1554 Grade 50
o Substructure
o Concrete:
4000 psi, 1 565 Cement Concrete for pier footing, lower half of
abutment, and approach slab
4000 psi, , 610 Cement Concrete for pier wall, pier diaphragms, keeper
blocks, and the upper half of abutment
4000 psi, 3/8, 705 Cement Concrete for pier pipe piles
5000 psi, , 685 HP Cement Concrete for retaining wall barriers
o Reinforcement: AASHTO M31, GRADE 60, epoxy coated
o Structural Steel: Uncoated weathering steel, AASHTO M270, Grade 50W
o High Strength Bolts:
All field connections shall be made with AASHTO M164 (A325)
o Anchor Rods: ASTM F1554 Grade 36

Preferred analysis methods and design approaches: All analysis and design will be
completed using the software listed below following guidelines from AASHTO. Load
and Resistance Factor Design shall be used for all superstructure, deck, and substructure
elements. The following elements have specific design criteria:
o Steel Plate-girder Design
Plate-girders will be designed using Merlin-Dash software.
Plate-girders shall be designed considering composite design, following
the steps outlined in the MassDOT Bridge Manual Chapter 3.
Load Distribution
Distribution of loads will be per MassDOT Bridge Manual
Section 3.5.3
Shear connectors

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Shear connectors will be used for composite design following

MassDOT Bridge Manual section 3.5.1.
Bolted Field Splices
Splices shall be designed following standards set by MassDOT
Bridge Manual section 3.6.5 and Standard detail 5.2.12.
Utility provisions
Non-composite sections carry the total dead load of utilities. See
framing plans for location of utility bay.
Dead load of utility is carried by the two stringers comprising the
bay
Top of Form Calculations: Top of form will be calculated as follows
Calculate the theoretical top of roadway elevation directly over the
beam at the required points along the span using a spreadsheet.
From this elevation, subtract the thickness of the wearing surface
and deck to obtain the in-place bottom of deck elevation. Include
for the thickness of the membrane if used.
To the in-place bottom of deck elevation, add the total dead load
deflection of the beam, excluding the deflection due to the beams
self-weight, calculated for the particular point along the beam
under consideration. The result is the top-of-form elevation.
Deflection and Camber Calculations
Live load deflection shall preferably be limited to 1/1000, but no
more than 1/800. Camber will be calculated at 10th points.
Camber and Deflection will be calculated per MassDOT Bridge
Manual Section 3.5.5

o Elastomeric bridge Bearing

The Elastomeric bearings will be designed per MassDOT Bridge Manual
Section 3.5.6
o Cast-in-place concrete deck
Cover distances from AASHTO Table 5.12.3-1 will be used.
Design shall be in accordance with the following standard details from the
MassDOT Bridge Manual (2009):
7.1.1 Typical Deck Reinforcement
7.1.5 Deck Slab Reinforcement Steel Stringers w/ HMA
7.1.13 Addl. Overhang Reinforcement: CF-PL3 Rail (w/ HMA)
7.1.21 Addl. Overhang Reinforcement Assumptions
o Abutment geometry and reinforcement:
An active earth pressure coefficient of Ka will be used to account for the
horizontal earth pressures per MassDOT Bridge Manual Section 3.1.5.
The non-seismic longitudinal forces for abutment design will be
determined per Section 3.3.1.3 of the MassDOT Bridge Manual.
o Pier geometry and reinforcement:
Live loads on the piers will be generated using a STAAD model.
The pier geometry and reinforcement design will be completed using the
LEAP Bridge Suite software RC Pier.
o Wingwall design
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An active earth pressure coefficient of Ka will be used to account for

horizontal earth pressures per MassDOT Bridge Manual Section 3.1.5.
A 10 kip horizontal collision force (2 kips per foot uniform load over a 5
foot length) will be considered under Extreme Event II limit state per
MassDOT Bridge Manual Section 3.3.2.2.
o Selection of piles
All dead and live loads, including impact, from the superstructure,
abutment, wingwalls, and half of the approach slab will be applied to the
piles. The capacity will be taken as the minimum of the structural or
geotechnical capacity of the piles.

Assumptions:
o See those stated above

Appropriate Validated Software: Merlin-Dash, STAAD, LEAP Bridge Suite RC Pier, LPile Group, MathCad, validated Microsoft Excel spreadsheets.
Construction Specifications: Designer should review Construction Specifications to
ensure consistency of material properties specified and construction methods to be used.

Interdisciplinary Coordination
Significant coordination with the Civil Department is required for geometry, utilities,
obstructions, and construction phasing.

END OF PROTOCOL

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