Prefabricated Steel Grid Bridge Decks

Philip M. Gase, P.E.

The DS Brown Company
DECK REPLACEMENT CONSIDERATIONS
Deteriorated bridge decks are the leading
cause of Structurally Deficient bridge
ratings

Higher than anticipated wheel loads

Corrosion

Service life of 40+ years

In many cases, deck replacement can
extend service life of structure and save
significant $$$
 WHY USE GRID DECKS?
When selecting a bridge deck, both initial costs and
life-cycle costs should be considered

Steel grid bridge decks are time-tested, economical

solutions for new or rehabilitated structures
Many grid reinforced concrete decks on structures with
50+ years of service:

South 10th St. Bridge (PADOT) 1932

Jerome St. Bridge (PADOT) 1937-1980 s
M. Harvey Taylor (PADOT) 1952-2001
Walt Whitman (Del River Port Auth) 1956
Mackinac (Mackinac Bridge Authority) 1957
Deck Weight ALUMINUM, FRP, ORTHOTROPIC

IMPORTANCE OF DECK WEIGHT

GRID DECKS
Reduction in deck DL
provides an increase in
LL rating
Further weight reduction
can be achieved using
REINFORCED
lightweight concrete
CONCRETE

Speed of Installation

Public impatient with bridge IMPORTANCE OF SPEED

construction congestion OF CONSTRUCTION

Focus of FHWA: Get In,

Get Out, Stay Out
Indirect cost savings
 Approved for
historical structures
such as Eads Bridge
over the Mississippi
required a strong,
lightweight system
(Originally opened
to traffic in 1874)

Commonly used for

lightweight deck on
moveable bridges such as
17th St. Causeway Bridge
in Ft. Lauderdale, FL
(spanning floorbeams
spaced @ 14.4 ft with no
stringers)
OPEN GRID SYSTEMS
First used in the
1920 s & is the
oldest lightweight
deck system
DIAGONAL GRID

It is the lightest grid

deck available,
however span
lengths are limited

RECTANGULAR GRID
OPEN GRID SYSTEMS

ADVANTAGES
Lightweight

DISADANTAGES
Noisy TYPICALLY ONLY USED FOR
Unpleasant ride quality REPLACEMENT IN KIND.

Possible safety issues

Allows debris and salt laden water through
Fatigue Prone
- Internally
- Connections to Stringers
FILLED GRID SYSTEMS
Full-depth grid was
introduced by engineers
in the 1930 s to speed
up construction on
large bridge projects

Can be precast or cast-in-place FULL-DEPTH

CONCRETE
for very quick installation; high FILLED GRID

performance to cost ratio

High durability and longevity are demonstrated

by the great service history
FILLED GRID SYSTEMS
Partially filled grid - first
used in the 1950 s to
further reduce weight by
eliminating concrete in
bottom tension zone

Can be precast or cast-in-place PARTIAL-DEPTH

CONCRETE
offering rapid construction; very FILLED GRID

good strength to weight ratio

Proven performance, this LW system offers

similar span capabilities to Full-Depth
EXODERMICTM DECK
Developed in the
early 1980 s
evolved from
traditional concrete
filled grid decks
AASHTO defines as unfilled
TM
EXODERMIC DECK

steel grid deck composite with a

reinforced concrete slab
Through optimizing the material properties
where they best fit, Exodermic decks have the
best strength to weight ratio
 EXODERMICTM DECK (+ MOMENT)

Concrete in Concrete in
Compression Compression

Steel in Steel in
Tension Tension
 EXODERMICTM DECK (- MOMENT)

Tension Tension

Compression Compression
 Partial-
Full-Depth ExodermicTM
Depth
Main
Rolled I or WT4, WT5, or
Member Rolled I
WT WT6
Component
Maximum
Up to 10 Up to 10 Greater than 10
Span Length
* Weight
65 75 psf 70 110 psf 60 70 psf
Range
* Total
7.25 5 to 7.25 6.5 to 9.5
Height

* Using 2 overfill/cover (AASHTO recommends

at least 1.75 for PD and FD grid decks)
FABRICATION
PROCESS

Members are
cut to length
and precisely
punched

Panels are
assembled

Assembled panels are welded together

Skews are cut into panels (If required)

Inspection is
performed
prior to
galvanizing

Panels are
galvanized for long-term corrosion protection

Inspection is performed once again after

galvanizing, and form pans placed prior to
shipment
 CAST-IN-PLACE CONSTRUCTION
The grid arrives at the job site as a pre-formed
deck, with very little additional formwork required

Rapid installation (up to 1000 SF/day)

Allows staged construction

Lightweight & durable

Conventional
installation process

Various barrier
options can be easily
incorporated
MATHEWS BRIDGE
JACKSONVILLE, FL
Originally built in 1952
with open grid for weight
savings

Direct link from east

side to downtown,
carrying approximately
74,000 vehicles per day

Closed deck system (ExodermicTM) was desired by FDOT

for ride quality and light weight also to protect the
superstructure from elements such as moisture and
debris therefore extending the life of the structure
FDOT only allowed a
90 day construction
period

New stringers were

provided at a larger
spacing of 5 -10 ½
to reduce DL

Using lightweight reinforced concrete the new deck

only weighs 48.8-lbs/sf while maintaining 2 cover

The project was completed two weeks early

installation rates averaging 400-500 SF/day
 OTHER CIP GRID PROJECTS
US 40 Over Susquehanna River (MTA)
386,000 SF of deck over 3 years (3 stages)
Average 13,000 SF/Mo.
ADT of approx 30,000

I-280 Stickel Bridge

(NJDOT)
Hyperbuild project
Nighttime & wknd
(3 stages)
430 SF/Day
ADT = 90,000
 PRECAST CONSTRUCTION

Heightened interest because of possibility for

rapid installation

Installation rates of over 1000 SF/day possible

MPT criteria drives design and construction

options:

Staged construction
Weekend work (full or partial closure)
Night time work (full or partial closure)
PRECAST DECK
PANELS
SETTING AND
LEVELING
CLOSURE POUR

Mobile mixer is recommended for rapid-

setting concrete
Vibrators required to consolidate concrete in
the shear keys and haunch areas
FINISHING

Commonly specified options for surface finishing after

installation of precast panels:

Diamond grind and seal

Prepare surface and place an epoxy overlay
Install a waterproofing membrane and an asphalt
overlay
I-285 CORRIDOR
ATLANTA, GA
I-285 over Cobb Pkwy
& Buford Highway were
built in the late 1950 s
and early 1960 s

Both previously
widened, the bridges
carry nearly 300,000
vehicles per day

Considering impacts of traffic and construction costs, a

precast full-depth grid with composite slab was selected
- total deck depth of only 6.5
The full-depth grid deck
- stringers spaced
between 6.5 & 7

Weekend lane closures

9pm Friday to 5am
Monday

Available weekends
limited to 16 - project
completed 5 weeks ahead
of schedule

Deck Area = 25,720 SF

(Avg = 2340 SF/wknd)
 TAPPAN ZEE BRIDGE (NYSTA)
130,000+ ADT

Maintain 4 of the 7
lanes for traffic
throughout night

8pm to 6am night

time closure with no
deck removal prior to
11pm (only about 6
hours to set panels)

259K SF total redecking, 2000 SF/night with one crew

$1300 per minute penalty for late opening

 OTHER PRECAST PROJECTS
Robert C. Beach Memorial (WVDOT)
30 day calendar window
Replace 5,400 SF of FRP with precast ExodermicTM
Completed 10 days early

M. Harvey Taylor Bridge (PADOT)

Full-depth panels set
during weekend closures
232,000 SF deck area
4000 SF/Weekend

Gowanus Expressway (NYC)

Weekend Closures
1900 SF/wknd
 KEY POINTS REGARDING THE USE OF
PREFABRICATED BRIDGE DECK PANELS
Grid reinforced concrete decks have a long successful
history

Careful planning and communication between owner,

design engineer & contractor is key to successful
completion

Precast panels must be properly handled and stored to

reduce chances of cracking

Durability of the system is affected by the number of cold

joints and connection detail at these locations

Rapid setting closure pour material is a very important

component of the system. Compromise between high-
early strength and shrinkage.
 BGFMA
Manufacturers
association
reformed in
June 2006

Goal is to
promote use of
grid reinforced
concrete decks

Composed of 4 full member and 4 associate

member companies