Professional Documents
Culture Documents
Alford B. Johnson - Steel Bridge Construction, Myths & Realities D432-07 R20090210A
Alford B. Johnson - Steel Bridge Construction, Myths & Realities D432-07 R20090210A
Construction:
Myths &
Realities
D432-07
Cosponsors
This publication was developed under the direction of the
American Iron and Steel Institute (AISI) and was co-sponsored
by the American Institute of Steel Construction (AISC) and the
National Steel Bridge Alliance (NSBA). AISI wishes to acknowl-
edge and express gratitude to Mr. Alford B. Johnson of MAGGY
Ventures, Inc., who was the principal author.
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6. Jointless Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15. Durability of Corrugated Steel Pipe and Corrugated Steel Plate in Bridge Applications . . . . . . . . . . . . . . . 21
19. Comparative Economics of Reinforced Concrete and Corrugated Steel in Bridge Applications . . . . . . . . . 23
This booklet is an updated and expanded version of the original document published in the mid-90s. Its
purpose is to dispel some of the “myths” or misconceptions surrounding the use of steel in bridge construction.
These myths often arise out of past experience and don’t take into account changes in technology, improve-
ments in materials and products or updated design and construction practices.
Adhering to these myths can limit the competitiveness of steel solutions, lead to misuse of steel products or
prevents designer and owners from taking advantage of viable options when it comes to providing crossings.
The original document focused primarily on signature bridges of steel plate girder construction. This new
document has been expanded to include prefabricated/modular steel bridges using steel rolled beams and
hollow structural sections and also corrugated steel pipe and corrugated steel plate as viable materials for
bridge construction.
The information is presented so that choices of framing materials can be made with more accurate knowledge
and in the most rational way possible. What follows is not intended to be an exhaustive treatise on the techni-
cal aspects of steel bridge design but rather to help designers and owners take full advantage of steel in their
search for viable solutions. To the extent possible we have provided references as back up and as sources for
additional information.
One item mentioned above, alkali-silica reaction 1 The demands of increasing age, traffic loading
(ASR), has been cited by the Strategic Highway and the increased use of road salts has made the
Research Program, as a major cause of cracking and durability of bridge structures of all types more
deterioration in concrete structures in the United difficult.
If corrosion protection of the concrete pier caps or Another example is a section of the New Jersey
abutments is desired any of the above sealers can be Turnpike that is close to the ocean, crosses many salt
combined with a clear or pigmented polyurethane marshes and passes through one of the worst area
topcoat. Such a system should provide 25 to 30 years of industrial pollution in the country. These bridges
of protection. have been in operation for years and continue to
perform very well.
There are also details that help divert the water
away from the concrete such as drip pans in Figure 3. In some cases a weathered appearance may not be
However, this method may be ineffective if the piers the first choice but this should not prevent owners
are very wide or tall as wind can carry diverted from benefiting from the economies of weathering
water back to the concrete surfaces. steel. In these cases the recommendation is to blast
clean and paint the outside surface of the fascia
girders only.
Figure 3: Drainage Details
The following example demonstrates the use of Figure 4–6: Plate Burning
the table. Evaluate splicing a plate 16" x 1" x 35' to
a plate 16" x 11⁄2" x 35' versus using a plate 16" x
11⁄2" x 70'. The weight saved by adding the splice is
equivalent to the weight of a plate 16" x 1⁄2" x 35'
(16" x 0.5" x 3.4 pounds/sq. inch x 35' = 952 pounds)
or about 950 pounds. The weight savings needed to
justify adding the splice is determined by using a
factor of 70 pounds per inch from the table, times
the plate width of 16", resulting in a value of 1,120
pounds. Because the actual saving is 950 pounds the
table indicates that it is more economical to extend
the 11⁄2" plate for the full 70' than to add the shop
splice.
........................................
MYTH: Bridge joints are essential.
REFERENCES:
........................................
M Y T H : Steel is not competitive for simple-span
bridges less than 140 feet in length.
National Steel Corrugated Steel Pipe Association. Reinforced concrete pipe uses a stab-joint type
Corrugated Steel Pipe Design Manual, 2007 joining method that is susceptible to gaps and open-
ings if the bedding has any imperfections or there
National Steel Corrugated Steel Pipe Association.
is differential settling or movement in the soil after
CSP Durability Guide, American Association of
installation. By contrast, corrugated steel pipe is
State Highway and Transportation Officials.
manufactured with re-corrugated ends and uses cor-
Standard Specification for Steel Sheet, Metallic-Coated
rugated external band couplers to provide a positive
and Polymer Pre-Coated, for Corrugated Steel Pipe,
and durable connection. In fact, these joints provide
M 246-05
the highest tensile and moment properties of any
pipe system.
REFERENCE:
CANADIAN
SYSTEM INITIAL TOTAL LIFE LCC COST AEAC (See A below)
COST/m2 CYCLE COST per m 2 per m 2
HDGB $21.11 $49,029 $21.11 $1.34
Inorganic zinc/epoxy $23.01 $143,217 $61.65 $3.91
FOOTNOTES
1 KTA Tator, Expected Service Life and Cost Considerations for Maintenance and New Construction Protective Coating Work,
Helsel, Melampy, Wissmar, 2006
2 American Galvanizers Association, National Survey, 2006
3 May vary due to regional differences, processing schedules, and London Metal Exchange price of zinc metal.
D432-MYTHS-0907-5000-AP