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Steel-concrete composite bridge design guide …

Steel-concrete composite bridge design guide September 2013 Raed El Sarraf, HERA, Auckland, New Zealand David Iles, SCI, Ascot, United Kingdom Amin Momtahan, AECOM, Auckland, New Zealand David Easey, AECOM, Auckland, New Zealand Stephen Hicks, HERA, Auckland, New Zealand NZ Transport Agency research report 525 ISBN 978-0-478- 40769-3 (electronic) ISSN 1173-3764 (electronic) NZ Transport Agency Private Bag 6995, Wellington 6141, New Zealand Telephone 64 4 894 5400; facsimile 64 4 894 6100 The New Zealand Heavy Engineering Research Association (HERA) was contracted by NZTA in 2009 to carry out this research El Sarraf, R, D Iles, A Momtahan, D Easey and S Hicks (2013) Steel-concrete composite bridge design guide . NZ Transport Agency research report 525. 252pp. HERA, HERA House, 17-19 Gladding Place, Manukau 2241, Auckland, New Zealand, telephone 64 9 262 4756, facsimile 64 9 262 2856, This publication is copyright NZ Transport Agency 2013.

Steel-concrete composite bridge design guide . September 2013 . Raed El Sarraf, HERA, Auckland, New Zealand . David Iles, SCI, Ascot, United Kingdom

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1 Steel-concrete composite bridge design guide September 2013 Raed El Sarraf, HERA, Auckland, New Zealand David Iles, SCI, Ascot, United Kingdom Amin Momtahan, AECOM, Auckland, New Zealand David Easey, AECOM, Auckland, New Zealand Stephen Hicks, HERA, Auckland, New Zealand NZ Transport Agency research report 525 ISBN 978-0-478- 40769-3 (electronic) ISSN 1173-3764 (electronic) NZ Transport Agency Private Bag 6995, Wellington 6141, New Zealand Telephone 64 4 894 5400; facsimile 64 4 894 6100 The New Zealand Heavy Engineering Research Association (HERA) was contracted by NZTA in 2009 to carry out this research El Sarraf, R, D Iles, A Momtahan, D Easey and S Hicks (2013) Steel-concrete composite bridge design guide . NZ Transport Agency research report 525. 252pp. HERA, HERA House, 17-19 Gladding Place, Manukau 2241, Auckland, New Zealand, telephone 64 9 262 4756, facsimile 64 9 262 2856, This publication is copyright NZ Transport Agency 2013.

2 Material in it may be reproduced for personal or in-house use without formal permission or charge, provided suitable acknowledgement is made to this publication and the NZ Transport Agency as the source. Requests and enquiries about the reproduction of material in this publication for any other purpose should be made to the Research Programme Manager, Programmes, Funding and Assessment, National Office, NZ Transport Agency, Private Bag 6995, Wellington 6141. Keywords: bridges, composite , concrete , construction, cost-effective, design , durability, efficiency, fabrication, fatigue, guide , ladder deck, life cycle, multi-girder, New Zealand, NZ Transport Agency, shear studs, steel , steel bridge Development Group, sustainability, vibration, welding. An important note for the reader The NZ Transport Agency is a Crown entity established under the Land Transport Management Act 2003.

3 The objective of the Agency is to undertake its functions in a way that contributes to an efficient, effective and safe land transport system in the public interest. Each year, the NZ Transport Agency funds innovative and relevant research that contributes to this objective. The views expressed in research reports are the outcomes of the independent research, and should not be regarded as being the opinion or responsibility of the NZ Transport Agency. The material contained in the reports should not be construed in any way as policy adopted by the NZ Transport Agency or indeed any agency of the NZ Government. The reports may, however, be used by NZ Government agencies as a reference in the development of policy. While research reports are believed to be correct at the time of their preparation, the NZ Transport Agency and agents involved in their preparation and publication do not accept any liability for use of the research.

4 People using the research, whether directly or indirectly, should apply and rely on their own skill and judgement. They should not rely on the contents of the research reports in isolation from other sources of advice and information. If necessary, they should seek appropriate legal or other expert advice. Acknowledgements This project was undertaken by the New Zealand Heavy Engineering Research Association (HERA), which is based in Manukau, Auckland City, New Zealand. The researchers gratefully acknowledge the following individuals and organisations for their support in the development of this document: Dr Charles Clifton of the University of Auckland Shane Culham of Culham Engineering Jacques De Reuck of Metal Spray Suppliers (NZ) Ltd Bob Delacey of George Grant Engineering Alistair Fussell of steel Construction New Zealand (SCNZ)

5 Phil Gaby of Holmes Consulting Group David Gifford of New Zealand steel Kenyon Graham of SKM Matthew Holland of Tenix Robt Stone Donald Kirkcaldie of Opus Peter Lipscombe of URS Jamie Macredie of Steltech Willie Mandeno of Opus Bruce Melsop of Eastbridge Amin Momtahan of AECOM David Moore of Grayson Engineering Will Pank of BECA Rob Presland of Holmes Consulting Group Anand Reddy of Holmes Consulting Group Craig Ross of Napier Sandblasting Dr Wolfgang Scholz of HERA Mike Sullivan of D&H Tony Vos of Altex Peter Wiles of Opus This report is a key deliverable of a three-year project that was part-funded by the New Zealand Transport Agency, the steel bridge Development Group and New Zealand steel Industry representatives. Abbreviations and acronyms BSI British Standards Institution CAE computer-aided engineering tools CEN European Committee for Standardization FCM fracture critical members IZS inorganic zinc silicate NZTA New Zealand Transport Agency RRU Road Research Unit, National Roads Board (predecessor of Transit NZ) SH state highway SLS serviceability limit state SNZ Standards New Zealand ULS ultimate limit state 5 Contents Executive summary.

6 7 Abstract .. 8 1 Introduction .. 9 2 Typical composite bridge configurations ..10 Multi-girder bridges .. 10 Ladder deck 14 Deck slab .. 20 Shear connection .. 21 Dealing with curvature and skew .. 21 Substructures .. 23 3 Benefits of Steel-concrete composite construction ..30 Why specify a composite bridge ? .. 30 Sustainability benefits .. 30 Economic benefits .. 32 New Zealand case studies .. 34 design concept .. 37 4 Preliminary design ..38 General .. 38 design for construction .. 38 design for in-service maintenance .. 42 Choice of structural configuration .. 44 Preliminary sizing material 45 Preliminary sizing multi-girder bridges .. 46 Preliminary sizing ladder decks .. 48 5 design standards ..49 The bridge manual .. 49 AS 5100 .. 50 NZS 3404 .. 50 NZS 3101.

7 51 BS 5400 .. 51 Eurocodes .. 51 Basis of design .. 51 Project-specific requirements .. 52 Health and safety regulations .. 52 6 Calculation of action effects ..53 Structural analysis .. 53 Computer modelling .. 55 Deck slab analysis .. 59 design loading and load 60 Seismic effects .. 65 7 Detailed design ..66 Overall bridge design .. 67 Main girders at ULS .. 69 6 design for bending .. 71 Shear resistance .. 81 SLS checks for compact and non-compact beams .. 82 design of restraints to beams .. 85 Longitudinal shear connection .. 88 Connections .. 94 Stiffeners .. 99 Deck slab 104 Fatigue design .. 108 Selection of steel sub-grade .. 111 8 Construction considerations .. 113 steel fabrication and concrete construction .. 113 Construction sequence .. 113 Cantilever edge slabs.

8 114 Allowance for permanent deformations .. 114 9 Detailing considerations .. 116 Geometric configurations .. 116 Cross girder end connections .. 119 Shear connection .. 123 Deck slab .. 124 Bearing specification .. 126 Deck joints .. 127 10 design of durable composite structures .. 128 Durability design of steel and concrete .. 128 An example of the durability design of steel .. 129 Coating application and inspection .. 137 Maintenance management .. 138 11 Other types of composite construction .. 139 composite box girders .. 139 Network arch bridges .. 14 0 Stainless steel in bridge construction .. 141 12 References .. 145 Appendix A: Two-lane, three and four girder bridge costs .. 149 Appendix B: Available plate dimensions .. 154 Appendix C: Initial sizing of main girders .. 156 Appendix D: Background to the fatigue design criteria for bridges.

9 157 Appendix E: Single span ladder deck bridge .. 160 Appendix F: Two span multi-girder bridge .. 186 Appendix G: Single span multi-girder bridge .. 231 7 Executive summary Steel-concrete composite bridges provide an efficient and cost-effective form of bridge construction. By utilising the tensile strength of steel in the main girder and the compressive strength of concrete in the slab, the bending resistance of the combined materials is greatly increased and larger spans are made possible. Two types of composite bridge are considered in this document. The typical multi-girder Steel-concrete composite bridge , which consists of a number of steel girders with bracing in between and a slab on top, and a ladder deck bridge , which consists of two main girders with a number of secondary cross girders in between that support and act with a deck slab.

10 Both provide a cost-effective solution and the choice between the two types depends on economic considerations and site-specific factors such as the form of intermediate supports and construction access. This research report provides guidance on the general considerations for the preliminary and detailed design process, in addition to guidance on the verification of structural adequacy in accordance with the NZ Transport Agency bridge manual and the relevant design and material standards. The guide describes the determination of design forces, identifies key features relating to the design of the different structural components and gives structural detailing advice. It also provides additional guidance on cost-effective design philosophy and durability design . The aim of the document is to provide guidance to both the novice and experienced bridge designer on the design of cost-effective Steel-concrete composite bridges.


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