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Deck Slab Bridge Design
Deck Slab Bridge Design
by
John Newhook
and
Gamil Tadro
Gamil Tadros
E-mail: gtadros@telus.net
gn
and
Gamil Tadros
f ISIS Canada
Empirical Design
bottom reinforcem
initial selections transverse bars (500d
girder deck select bar dia. req'd. bar area req'd bar
spacing thickness bot. trans. db ds Af pick bar Af spacing
(mm) (mm) bar size (mm) (mm) (mm2/m) size (mm2) (mm)
2,900 175 #6 19.1 130 1510 #6 285 189
2,900 175 #6 19.1 130 1510 #6 285 189
2,900 175 #6 19.1 130 1510 #6 285 189
top reinforcemen
transverse bars ( = 0.0035)
girder req'd. bar area req'd bar
Haunch NU Flange spacing Af pick bar Af spacing
(mm) (mm) (mm) (mm2/m) size (mm2) (mm)
20 40 2900 457 #6 285 624
2900 457 #6 285 624
2900 457 #6 285 624
Design Summary
Option 3 All GFRP
Reinforcement
GFRP GFRP GFRP GFRP
Girder Deck Top Trans. Top Long. Bottom Long. Bottom Trans.
Spacing Thickness Size Spacing Size Spacing Size Spacing Size
(mm) (mm) (mm) (mm) (mm)
2,900 175 #6 175 #4 275 #4 275 #6
2,900 175 #6 150 #4 275 #4 275 #6
2,900 175 #6 135 #4 275 #4 275 #6
Thickness Limits
d Truck CL 800 kN
DLA 0.4
Wheel 0.14 % of Truck
asphalt Factor 0.9
Mdeck
(kN-m/m)
0.5
0.5
0.5
j
0.939
0.935
0.932
limit
(mm)
0.5
0.5
0.5
j
0.950
0.945
0.942
limit
(mm)
0.5
0.5
0.5
GFRP
Bottom Trans. Crack Width
Spacing Top Bottom
(mm) (mm) (mm)
175 0.63 1.09
150 0.51 0.84
135 0.43 0.70
CFRP-Reinforced Deck
Option 4. all CFRP
Empirical Design
bottom reinforcem
initial selections transverse bars (500d
girder deck select bar dia. req'd. bar area req'd bar
spacing thickness bot. trans. db ds Af pick bar Af spacing
(mm) (mm) bar size (mm) (mm) (mm2/m) size (mm2) (mm)
2900 175 #4 12.0 134 540 #4 108 200
2900 175 #4 12.0 134 540 #4 108 200
2900 175 #4 12.0 134 540 #4 108 200
top reinforcemen
transverse bars ( = 0.0035)
girder req'd. bar area req'd bar
Haunch NU Flange spacing Af pick bar Af spacing
(mm) (mm) (mm) (mm2/m) size (mm2) (mm)
20 40 2900 469 #4 108 231
2900 469 #4 108 231
2900 469 #4 108 231
Design Summary
Option 4 All CFRP
Reinforcement
CFRP CFRP CFRP CFRP
Girder Deck Top Trans. Top Long. Bottom Long. Bottom Trans.
Spacing Thickness Size Spacing Size Spacing Size Spacing Size
(mm) (mm) (mm) (mm) (mm)
2900 175 #4 175 #4 225 #4 225 #4
2900 175 #4 150 #4 225 #4 225 #4
2900 175 #4 125 #4 225 #4 225 #4
Thickness Limits
d Truck CL 800 kN
DLA 0.4
Wheel 0.14 % of Truck
asphalt Factor 0.9
Mdeck
(kN-m/m)
0.5
0.5
0.5
j
0.939
0.937
0.933
limit
(mm)
0.5
0.5
0.5
j
0.948
0.943
0.939
limit
(mm)
0.5
0.5
0.5
CFRP
Bottom Trans. Crack Width
Spacing Top Bottom
(mm) (mm) (mm)
185 0.56 1.03
170 0.44 0.89
150 0.32 0.71
FRP-Hybrid Reinforced Deck
Option 5. CFRP bottom transverse, GFRP elsewhere
Empirical Design
bottom reinforcem
initial selections CFRP transverse bars (500d
girder deck select bar dia. req'd. bar area req'd bar
spacing thickness bot. trans. db ds Af pick bar Af spacing
(mm) (mm) bar size (mm) (mm) (mm2/m) size (mm2) (mm)
2900 175 #4 12.0 134 540 #4 108 200
2900 175 #4 12.0 134 540 #4 108 200
2900 175 #4 12.0 134 540 #4 108 200
top reinforcemen
GFRP transverse bars ( = 0.0035)
girder req'd. bar area req'd bar
Haunch NU Flange spacing Af pick bar Af spacing
(mm) (mm) (mm) (mm2/m) size (mm2) (mm)
20 40 2900 469 #6 285 608
2900 469 #6 285 608
2900 469 #6 285 608
Design Summary
Option 5 FRP- Hybrid
Reinforcement
GFRP GFRP GFRP CFRP
Girder Deck Top Trans. Top Long. Bottom Long. Bottom Trans.
Spacing Thickness Size Spacing Size Spacing Size Spacing Size
(mm) (mm) (mm) (mm) (mm)
2900 175 #6 175 #4 270 #4 270 #4
2900 175 #6 150 #4 270 #4 270 #4
2900 175 #6 135 #4 270 #4 270 #4
Thickness Limits
d Truck CL 800 kN
DLA 0.4
Wheel 0.14 % of Truck
asphalt Factor 0.9
Mdeck
(kN-m/m)
0.5
0.5
0.5
j
0.939
0.937
0.933
limit
(mm)
0.5
0.5
0.5
j
0.950
0.945
0.942
limit
(mm)
0.5
0.5
0.5
CFRP
Bottom Trans. Crack Width
Spacing Top Bottom
(mm) (mm) (mm)
185 0.63 1.03
170 0.51 0.89
150 0.43 0.71
Steel -FRP Hybrid Reinforced Deck
Option 6. Steel bottom layer, GFRP top layer
Empirical Design
= 0.003 steel bottom reinforc
initial selections transverse bars
girder deck select bar dia. req'd. bar area req'd bar
spacing thickness bot. trans. db d As pick bar As spacing
(mm) (mm) bar size (mm) (mm) (mm2/m) size (mm2) (mm)
2,900 200 15M 16 142 426 15M 200 469
2,900 200 15M 16 142 426 15M 200 469
2,900 200 15M 16 142 426 15M 200 469
top reinforcemen
GFRP transverse bars ( = 0.0035)
girder req'd. bar area req'd bar
Haunch NU Flange spacing Af pick bar Af spacing
(mm) (mm) (mm) (mm2/m) size (mm2) (mm)
20 40 2,900 497 #6 285 573
2,900 497 #6 285 573
2,900 497 #6 285 573
Design Summary
Option 6 Steel-FRP Hybrid
Reinforcement
GFRP GFRP black steel black steel
Girder Deck Top Trans. Top Long. Bottom Long. Bottom Trans.
Spacing Thickness Size Spacing Size Spacing Size Spacing Size
(mm) (mm) (mm) (mm) (mm)
2900 200 #6 200 #4 225 15M 300 15M
2900 200 #6 185 #4 225 15M 300 15M
2900 200 #6 165 #4 225 15M 300 15M
Thickness Limits
d Truck CL 800 kN
DLA 0.4
Wheel 0.14 % of Truck
asphalt Factor 0.9
Mdeck
(kN-m/m)
0.5
0.5
0.5
om transverse bars
Ab
j (mm2)
0.916 200
0.916 200
0.912 200
k width calculations
kc c db Srm c w limit
(mm) (mm) (mm)
0.5 0.0146 16 187 1.7 0.56 0.25
0.5 0.0146 16 187 1.7 0.56 0.25
0.5 0.0164 16 172 1.7 0.47 0.25
j
0.956
0.953
0.950
limit
(mm)
0.5
0.5
0.5
black steel
Bottom Trans. Crack Width
Spacing Top Bottom
(mm) (mm) (mm)
250 0.70 0.56
250 0.63 0.56
225 0.52 0.47
Externally Restrained Deck
Option 7. GFRP crack control, steel straps
Empirical Design
Design Summary
Reinforcement
Deck Top Trans. Top Long. Bottom Long.
Thickness Size Spacing Size Spacing Size
Option Description (mm) (mm) (mm) (mm) (mm) (mm)
1 black steel 225 15M 300 15M 300 15M
2 epoxy steel 225 15M 300 15M 300 15M
3 GFRP 175 #6 175 #4 275 #4
4 CFRP 175 #4 175 #4 225 #4
5 GFRP/CFRP 175 #6 175 #4 270 #4
6 GFRP/steel 200 #6 200 #4 225 15M
Straps
thickness
(mm)
7 externally restrained 175 #4 300 #4 300 25
Reinforcement
Deck Top Trans. Top Long. Bottom Long.
Thickness Size Spacing Size Spacing Size
Option Description (mm) (mm) (mm) (mm) (mm) (mm)
1 black steel 225 15M 250 15M 250 15M
2 epoxy steel 225 15M 250 15M 250 15M
3 GFRP 175 #6 150 #4 275 #4
4 CFRP 175 #4 150 #4 225 #4
5 GFRP/CFRP 175 #6 150 #4 270 #4
6 GFRP/steel 200 #6 185 #4 225 15M
Straps
thickness
(mm)
7 externally restrained 175 #4 300 #4 300 25
Reinforcement
Deck Top Trans. Top Long. Bottom Long.
Thickness Size Spacing Size Spacing Size
Option Description (mm) (mm) (mm) (mm) (mm) (mm)
1 black steel 225 15M 200 15M 200 15M
2 epoxy steel 225 15M 200 15M 200 15M
3 GFRP 175 #6 135 #4 275 #4
4 CFRP 175 #4 125 #4 225 #4
5 GFRP/CFRP 175 #6 135 #4 270 #4
6 GFRP/steel 200 #6 165 #4 225 15M
Straps
thickness
(mm)
7 externally restrained 200 #4 300 #4 300 25
rcement
Bottom Long. Bottom Trans. Crack Width
Spacing Size Spacing Top Bottom
(mm) (mm) (mm) (mm) (mm)
300 15M 300 0.41 0.66
300 15M 300 0.49 0.79
275 #6 175 0.63 1.09
225 #4 185 0.56 1.03
270 #4 185 0.63 1.03
300 15M 250 0.70 0.56
Straps
x width spacing
(mm) (mm)
35 1200
rcement
Bottom Long. Bottom Trans. Crack Width
Spacing Size Spacing Top Bottom
(mm) (mm) (mm) (mm) (mm)
250 15M 250 0.30 0.48
250 15M 250 0.36 0.57
275 #6 150 0.51 0.84
225 #4 170 0.44 0.89
270 #4 170 0.51 0.89
300 15M 250 0.63 0.56
Straps
x width spacing
(mm) (mm)
65 1200
rcement
Bottom Long. Bottom Trans. Crack Width
Spacing Size Spacing Top Bottom
(mm) (mm) (mm) (mm) (mm)
200 15M 200 0.21 0.32
200 15M 200 0.25 0.39
275 #6 135 0.43 0.70
225 #4 150 0.32 0.71
270 #4 150 0.43 0.71
300 15M 225 0.52 0.47
Straps
x width spacing
(mm) (mm)
65 1200
Basic Cost database
Cost ($ /units)
Component units Supply Install Total search
Reinforcement code
black steel kg $2.10 black $2.10
epoxy-coated steel kg $3.00 epoxy $3.00
galvanized steel kg $3.00 galv $3.00
stainless steel clad kg $8.00 MMFX $3.50
stainless steel solid kg $12.00 SS clad $8.00
MMFX steel kg $3.50 SS soild $12.00
GFRP #3 m $1.85 $1.00 $2.85 #3 $2.85
GFRP #4 m $2.85 $1.15 $4.00 #4 $4.00
GFRP #5 m $4.15 $1.40 $5.55 #5 $5.55
GFRP #6 m $5.95 $1.80 $7.75 #6 $7.75
GFRP #8 m $9.50 $2.00 $11.50 #8 $11.50
CFRP #3 m $15.00 $2.00 $17.00 #3 $17.00
CFRP #4 m $25.00 $2.00 $27.00 #4 $27.00
Other Deck Materials blank1 $0.00
formwork m2 $120.00 blank2 $120.00
concrete - FRC m3 $300.00 FRC $300.00
concrete - normal m3 $220.00 HPC $440.00
concrete - HPC m3 $440.00 normal $220.00
asphalt only 50 mm m2 $35.00 asphalt $35.00
concrete wearing coarse 15 mm m2 $7.00 concrete $7.00
high density concrete m2 $70.00 HD overlay $70.00
membrane and asphalt m2 $60.00 membrane $60.00
polymer modified asphalt - 50 mm m2 $45.00 PMA $45.00
steel straps kg $4.00 none $4.00
steel
bar kg/m
10M 0.785
15M 1.57
20M 2.355
Option Costs per Square Metre of Bridge Deck
reinforcement
top transverse - black top longitudinal - black
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/kg) (mm) (kg) ($/kg) (mm) (kg)
15M $2.10 300 15.2 $32 15M $2.10 300 15.2
15M $2.10 250 18.2 $38 15M $2.10 250 18.2
15M $2.10 200 22.8 $48 15M $2.10 200 22.8
bottom transverse - black bottom longitudinal - black
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/kg) (mm) (kg) ($/kg) (mm) (kg)
15M $2.10 300 15.2 $32 15M $2.10 300 15.2
15M $2.10 250 18.2 $38 15M $2.10 250 18.2
15M $2.10 200 22.8 $48 15M $2.10 200 22.8
reinforcement
top transverse - epoxy top longitudinal - epoxy
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/kg) (mm) (kg) ($/kg) (mm) (kg)
15M $3.00 300 15.2 $46 15M $3.00 300 15.2
15M $3.00 250 18.2 $55 15M $3.00 250 18.2
15M $3.00 200 22.8 $68 15M $3.00 200 22.8
bottom transverse - epoxy bottom longitudinal - epoxy
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/kg) (mm) (kg) ($/kg) (mm) (kg)
15M $3.00 300 15.2 $46 15M $3.00 300 15.2
15M $3.00 250 18.2 $55 15M $3.00 250 18.2
15M $3.00 200 22.8 $68 15M $3.00 200 22.8
reinforcement
top transverse - GFRP top longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#6 $7.75 175 16.6 $128 #4 $4.00 275 10.5
#6 $7.75 150 19.3 $150 #4 $4.00 275 10.5
#6 $7.75 135 21.5 $166 #4 $4.00 275 10.5
bottom transverse - GFRP bottom longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#6 $7.75 175 16.6 $128 #4 $4.00 275 10.5
#6 $7.75 150 19.3 $150 #4 $4.00 275 10.5
#6 $7.75 135 21.5 $166 #4 $4.00 275 10.5
reinforcement
top transverse - GFRP top longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#6 $7.75 175 16.6 $128 #4 $4.00 270 10.7
#6 $7.75 150 19.3 $150 #4 $4.00 270 10.7
#6 $7.75 135 21.5 $166 #4 $4.00 270 10.7
bottom transverse - CFRP bottom longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#4 $27.00 185 15.7 $423 #4 $4.00 270 10.7
#4 $27.00 170 17.1 $461 #4 $4.00 270 10.7
#4 $27.00 150 19.3 $522 #4 $4.00 270 10.7
reinforcement
top transverse - GFRP top longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#6 $7.75 200 14.5 $112 #4 $4.00 225 12.9
#6 $7.75 185 15.7 $121 #4 $4.00 225 12.9
#6 $7.75 165 17.6 $136 #4 $4.00 225 12.9
bottom transverse - black bottom longitudinal - black
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
15M $2.10 250 18.2 $38 15M $2.10 300 15.2
15M $2.10 250 18.2 $38 15M $2.10 300 15.2
15M $2.10 225 20.2 $42 15M $2.10 300 15.2
reinforcement
top transverse - GFRP top longitudinal - GFRP
Size unit cost Spacing Quantity cost Size unit cost Spacing Quantity
($/m) (mm) (m) ($/m) (mm) (m)
#4 $4.00 300 9.7 $39 #4 $4.00 300 9.7
#4 $4.00 300 9.7 $39 #4 $4.00 300 9.7
#4 $4.00 300 9.7 $39 #4 $4.00 300 9.7
straps
thickness width Spacing Quantity cost
(mm) (mm) (mm) (kg)
25 35 1200 48.1 $193
25 55 1200 75.6 $303
25 65 1200 89.4 $358
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $737
asphalt $35 $102 $737
asphalt $35 $102 $737
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $127
$32 2.9 $153
$38 2.9 $191
$48
Option Cost
cost Sg Total
(m) ($/m2)
$32 2.9 $298
$38 2.9 $307
$48 2.9 $320
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $737
asphalt $35 $102 $737
asphalt $35 $102 $737
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $182
$46 2.9 $219
$55 2.9 $273
$68
Option Cost
cost Sg Total
(m) ($/m2)
$46 2.9 $317
$55 2.9 $329
$68 2.9 $348
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $561
asphalt $35 $102 $561
asphalt $35 $102 $561
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $341
$42 2.9 $384
$42 2.9 $417
$42
Option Cost
cost Sg Total
(m) ($/m2)
$42 2.9 $311
$42 2.9 $326
$42 2.9 $337
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $561
asphalt $35 $102 $561
asphalt $35 $102 $561
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $1,567
$348 2.9 $1,679
$348 2.9 $1,844
$348
Option Cost
cost Sg Total
(m) ($/m2)
$348 2.9 $734
$348 2.9 $772
$348 2.9 $830
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $561
asphalt $35 $102 $561
asphalt $35 $102 $561
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $638
$43 2.9 $696
$43 2.9 $774
$43
Option Cost
cost Sg Total
(m) ($/m2)
$43 2.9 $413
$43 2.9 $434
$43 2.9 $461
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $705
asphalt $35 $102 $705
asphalt $35 $102 $705
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $234
$52 2.9 $243
$52 2.9 $262
$52
Option Cost
cost Sg Total
(m) ($/m2)
$32 2.9 $324
$32 2.9 $327
$32 2.9 $333
topping sub-total
type unit cost cost decking
($/m2)
asphalt $35 $102 $602
asphalt $35 $102 $602
asphalt $35 $102 $624
reinforcing
Sg sub-total
cost (m) reinf'g
2.9 $270
$39 2.9 $380
$39 2.9 $435
$39
Option Cost
Sg Total
(m) ($/m2)
2.9 $301
2.9 $339
2.9 $365
search
codes
black
epoxy
galv
MMFX
SS clad
SS soild
#3
#4
#5
#6
#8
#3
#4
FRC
HPC
normal
asphalt
concrete
HD overlay
membrane
PMA
none
Summary of Construction Costs
Option
Girder Spacing (m) 1 2 3 4 5 6
Total Cost ($/m2)
2.9 $298 $317 $311 $734 $413 $324
2.9 $307 $329 $326 $772 $434 $327
2.9 $320 $348 $337 $830 $461 $333
Ratio of cost with Option 1
2.9 1.00 1.06 1.04 2.46 1.39 1.09
2.9 1.00 1.07 1.06 2.52 1.41 1.07
2.9 1.00 1.09 1.05 2.59 1.44 1.04
Concrete Deck Costs ($/m2)
2.9 $99 $99 $39 $39 $39 $88
2.9 $99 $99 $39 $39 $39 $88
2.9 $99 $99 $39 $39 $39 $88
Top Reinforcement Costs ($/m2)
2.9 $22 $31 $59 $274 $59 $57
2.9 $26 $38 $66 $300 $66 $60
2.9 $33 $47 $72 $336 $72 $65
Bottom Reinforcement Costs ($/m2)
2.9 $22 $31 $59 $266 $161 $24
2.9 $26 $38 $66 $279 $174 $24
2.9 $33 $47 $72 $300 $195 $26
7
$301
$339
$365
1.01
1.10 cost temporary worksheet
1.14 1 2 3 4 5 6 7
Concrete Deck Costs ($ per section area)
$53 287.10 287.10 111.65 111.65 111.65 255.20 152.25
$53 287.10 287.10 111.65 111.65 111.65 255.20 152.25
$60 287.10 287.10 111.65 111.65 111.65 255.20 174.00
2)
$27 63.74 91.06 170.61 795.43 171.39 163.93 77.33
$27 76.49 109.27 192.02 870.00 192.80 173.04 77.33
$27 95.61 136.59 208.66 974.40 209.44 187.77 77.33
m2)
$66 63.74 91.06 170.61 771.24 466.21 70.12 192.55
$104 76.49 109.27 192.02 808.59 503.55 70.12 302.58
$123 95.61 136.59 208.66 870.00 564.96 74.37 357.60
section
area
2.9
2.9
2.9