MANUAL FOR CONDITION EVALUATION OF BRIDGES 1994 Prepared by the AASHTO Subcommittee on Bridges and Structures © Copyright 1994 by the American Association of State Highway and Trans- portation Officials. All Rights Reserved. This book, or any part thereof, must not be reproduced in any form without the written permission ofthe publisher. ISBN: 1-56051-067-6 Published by the ‘American Association of State Highway and Transportation Officials ‘444 North Capitol Street, N.W,, Suite 249 Washington, D.C. 20001AASHTO EXECUTIVE COMMITTEE 1992-1993 VOTING MEMBERS Officers President: Wayne Muri, Missouri Vice President: Howard Yerusalim, Pennsylvania Secretary. Clyde E. Pyers, Maryland Regional Representatives Region! Charles O'Leary, New Hampshire Region Hl Wayne Shackelford, Georgia Region IMI Kirk Brown, Ilinois Region IV (vacant) NON-VOTING MEMBERS Immediate Past President: A. Ray Chamberlain, Colorado Executive Director: Francis B. Francois, Washington, D.C.HIGHWAY SUBCOMMITTEE ON BRIDGES AND STRUCTURES 1993 JAMES E. SIEBELS, COLORADO, Chairman G. CHARLES LEWIS, GEORGIA, Vice Chairman STANLEY GORDON, Federal Highway Administration, Secretary ALABAMA, Fred Conway ALASKA. Steve Bradford, Ray Shumway ARIZONA, William R. Brucsch, F. Daniel Davis ARKANSAS, Veral Pinkerton CALIFORNIA, James E. Roberts COLORADO, AJ. Siccardi CONNECTICUT, Gordon Barton DELAWARE, Chao H. Hu D.., Charles F. Williams, Jacob Patnaik FLORIDA, Jerry Potter GEORGIA, Paul Liles HAWAII, Donald C. Omellas IDAHO, Richard Jobes ILLINOIS, Ralph E. Anderson INDIANA, John J. White IOWA, William A. Lundquist KANSAS, Kenneth F, Hurst KENTUCKY, Richard Sutherland LOUISIANA, Norval Knapp MAINE, James Chandler, Theodore Karasopoulos MARYLAND, Earle S. Freedman MASSACHUSETTS, Joseph P. Gill MICHIGAN, Sudhakar Kulkami MINNESOTA, Donald J. Flemming MISSISSIPPI, Wilbur Frank Massey MISSOURI, Allen F. Laffoon MONTANA, James C. Hill NEBRASKA, Lyman D. Freemon NEVADA, Floyd I. Marcucci NEW HAMPSHIRE, James A. Moore NEW JERSEY, Robert Pege NEW MEXICO, Martin A. Gavumnick NEW YORK, Michael J. Cuddy, Arun Shirole NORTH CAROLINA, John L. Smith NORTH DAKOTA, Forest Durow OHIO, B. David Hanhilammi OKLAHOMA, Veldo M. Goins OREGON, Terry J. Shike PENNSYLVANIA, Mahendra G. Patel PUERTO RICO, Jorge L. Melendez, Jorge L. Acevedor, RHODE ISLAND, Kazem Fahhoumand SOUTH CAROLINA, Benjamin A. Meetze SOUTH DAKOTA, Clyde H. Jundt ‘TENNESSEE, Clellon Loveall, Ed Wasserman ‘TEXAS, Luis Ybanez USS. DOT, Stanley Gordon (FHWA), Nick E. Mpars (USCG) UTAH, Dave Christensen VERMONT, Warren B. Tripp VIRGINIA, Malcolm T. Kerley WASHINGTON, Allan H. Walley WEST VIRGINIA, James Sothen WISCONSIN, Stanley W. Woods WYOMING, David Pope ALBERTA, Bob Ramsay MANITOBA, W. Saltzberg MARIANA ISLANDS, Elizabeth H. Salas- Balajadia NEW BRUNSWICK, Garth Rushton NEWFOUNDLAND, Peter Lester NORTHWEST TERRITORIES, Jivko Jivkov NOVA SCOTIA, Stan Nguan ONTARIO, Rajit S. Reel SASKATCHEWAN, Lome J. Hamblin MASS. METRO. DIST. COMM., David Lenhardt NJ. TURNPIKE AUTHORITY, Wallace R. Grant PORT AUTHORITY OF NY & NJ, Joseph K. Kelly NY STATE BRIDGE AUTHORITY, William Moreau BUREAU OF INDIAN AFFAIRS-DIVISION OF ‘TRANSPORTATION, Wade Cosey US, DEPARTMENT OF AGRICULTURE- FOREST SERVICE, Steve L. Bunnell MILITARY TRAFFIC MANAGEMENT COMMAND, Robert D. Franz U.S. ARMY CORPS OF ENGINEERS-DEPT. OF ‘THE ARMY, Paul C.T. TanTABLE OF CONTENTS 1.6.1 Definitions Page ACKNOWLEDGEMENT .... x 1. INTRODUCTION .. 1 LI PURPOSE 1 12 ScOpEI et 1 13. APPLICABILITY z 1 14 QUALITY MEASURES .. 1 1.5 BRIDGE MANAGEMENT SYSTEMS 1 1.6 DEFINITIONS AND IMPORTANT REFERENCES 1 1 2 BRIDGE FILE (RECORDS) 24 22 23 24 1.62 Important References... GENERAL COMPONENTS OF BRIDGE RECORDS a 22.1.1” Construction Plans 2.2.1.2 Shop and Working Drawings 22.13 As-Built Drawings ... 222 Specifications ' 223 Correspondence .. 224 Photographs 225° Materials and Tests no 2.25.1 Material Certfication 22.5.2 Material Test Data .... 2253 Load Test Data 226 Maitnane and Repair Histy 22.7 Coating History 228 Accident Records 229 Posting 22.10 Permit Loads 22.11 Flood Data 22.12 Traffic Data 22.13 Inspection History ... 2.2.14 Inspection Requirements .... 2.2.15 Structure Inventory and Appraisal Sheets . 2.2.16 Inventories and Inspections... 2.2.17 Rating Records .. INVENTORY DATA. 23D General rn 232 _ Revised Inventory Data INSPECTION DATA 24.1 General 24.2 Revised Inspection Data25 26 INSPECTION 31 32 33 34 35 36 BT CONDITION AND LOAD RATING DATA. 28.1 General nnn 2.5.2 Revised Conditions anc LOCAL REQUIREMENTS .... Load Rating Data GENERAL TYPES eos 3.2.1 Initial Inspections 322 Routine Inspections 32.3 Damage Inspections 3.24 In-Depth Inspections 3.25 Special Inspections FREQUENCY recon 35.1 General 35.2 Personnel Safety 353 Public Safety . PLANNING, SCHEDULING AND 36.1 Planning . 3.62 Scheduling 363 Equipment nn 7 3.63.1 Access Methods and Equipment 3.6.3.2 Inspection Methods and Equipment INSPECTION FORMS AND REPORTS oe PROCEDURES ....... : 38.1 General 3812 Cleaning smn emia 381.3 Guidelines for Condition Rating of Bridge Components 38.14 Critical Deficiency Procedures =... - 38.2 Substructure «nnn 382.1 Abutments ... 3.822 Retaining Walls 3823 Piers and Bents 3824 Pile Bent. a 38.25 Bridge Stability and Movements 3.82.6 Dolphins and Fenders... 3.83 Superstrucure 2 ; Steel Beams, Girders and Box Sections . Reinforced Concrete Beams and Girders _ Prestressed Concrete Beams, Girders and Box Sections Timber Systems se Floor Systems .... Trusses. Cables ... Diaphragms and Cross Frames. Lateral Bracing, Portals and Sway Frames Rivets, Bolts and Welded Connections .. Pins and Hangers ..39 3.10 3. 3.12 MATERIAL TESTING 41 42 3.83.12 Bearings 383.13 Paint 383.14 Utilities. 383.15 Arches . BBA DECKS onan 3.84.1 Concrete Decks 3.84.2 Prestressed Concrete Deck Panels 3.843 Steel Decks 3.844 Timber Decks 3.843 Expansion Joints z 3.84.6 Railings, Sidewalks and Curbs 3.8.4.6.1 Railings 3.84.62 Sidewalks and Curbs. 3.84.7 Bridge Drainage 3.848 Lighting 3849 Deck Ove 385 Approaches . 3.85.1 Pavement .. 3.85.2 Drainage ...... 3.85.3 Traffic Safety Features 3.854 Embankment Slopes 3.86 Signs ... oe 387 Waterways. 3.88 Box Culverts as Bridges .... 3.89 Corrugated Metal Plate Structures... 3.8.10 Encroachments . SPECIAL STRUCTURES 39.1 Movable Bridges .. 3.9.2 Suspension Spans 39.3 Cable-Stayed Bridges... 3.9.4 Prestressed Concrete Segmental Bridges UNDERWATER INSPECTIONS i 3.10.1 Routine Underwater Inspections. 3.10.2 In-Depth Underwater Inspections with Divers FATIGUE PRONE DETAILS .... = FRACTURE CRITICAL MEMBERS GENERAL .... FIELD TESTS oon 4.2.1 Concrete Field Tests ‘Strength Methods ‘Sonic Methods Ultrasonic Techniques Magnetic Methods Electrical Methods Nuclear Methods... ‘Thermography Radar Radiography. 42.110 Endoscopes 42.2 Steel Field Tests nn 42.21 Radiography... 42.22 Magnetic Particle Examination4.2.23. Eddy Curent Examination ... 4.2.2.4 Dye Penetrant Examination 4.2.2.5 Ultrasonic Examination 42.3 Timber Field Tests 4.23.1 Penetration Methods 42.32 Electrical Methods 42.3.3 Ultrasonic Techniques 4.3. MATERIAL SAMPLING von 44 LABORATORY TESTS .. 4.5 INTERPRETATION AND EVALUATION OF TEST RESULTS 4.6 TESTING REPORTS NON-DESTRUCTIVE LOAD TESTING LOAD RATING 6.1 GENERAL . 6.1.1 Assumptions 6.12 Substructure Consideration 6.13 Safety Criteria . 6.14 Application of Standard Design Speciation 6.1.5 Nonredundant Structures 6.1.6 Load Rating for Complex Structures. 62 QUALIFICATIONS AND RESPONSIBILITIES 63 RATING LEVELS 6.3.1 Inventory Rating Level 632 Operating Rating Level 64 RATING METHODS ....... 64.1 Allowable Stress (AS) 64.2 Load Factor (LF) 6.5 RATING EQUATION .. 65.1 General in 65.2 Allowable Stress . 65.3 Load Factor 65.4 Condition of Bridge Members 6.5.5 Bridges with Unknown Structural Components 66 NOMINAL CAPACITY (C) . 66.1 General 66.2 Allowable Stress Method 66.2.1 Structural Steel .... 6.6.2.1.1 Combined Stresses 66.2.1.2 Batten Plate Compression Members 6.6.2.2 Wrought Iron .. . 66.2.3 Reinforcing Steel 6.6.24 Concrete i 6624.1 Bending .... 662.42 Columns . ‘ 66.2.4.3 Shear (Diagonal Tension) 6.6.2.5 Prestressed Concrete win 6.6.2.6 Masonry rn 6.6.2.7 Timber 6.6.3 Load Factor Method 6.6.3.1 Structural Stee! 66.3.2 Reinforced Concrete 66.3.3 Prestressed Concrete