Chapter 3: Designing Steel Bridges Using DCALC By Karl Hanson, S.E., P.E. July 2006

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1 Chapter 3: Designing Steel Bridges Using DCALC By Karl Hanson, S.E., P.E. July Introduction: This chapter is an overview showing how to a design typical highway bridges using DCALC. We will look at the overall process, and direct the reader to the various programs. DCALC is installed with several examples that are located in the C:\DCALC\DEMO directory. Two bridge design examples are included: a steel wide flange bridge and a precast prestressed concrete beam bridge. There is essentially little different in the approaches used in the design of both types of bridges, except for the design of the beams. 3.2 Steel Beam Bridge Design Example: We can explain the process of using DCALC by walking through an example showing how to design a steel beam bridge. This example will be taken from an actual bridge that was constructed in Chicago. There are ramps on each side of the main bridge, which we will ignore for the purposes of this exercise. The main bridge consists of ten straight wide flange W36 beams having steel with a yield stress of 50 ksi. Actual structure consists of two ramps and Unit 1 of a viaduct p.3-1

2 3.2 Steel Beam Bridge Design Example (Cont d): Profile Grade Cross-Section Thru Superstructure Deck Plan p.3-2

3 3.3. Starting The Design As general housekeeping practice, with any bridge design the first thing that you will need to do is collect geometrical information. This following information is required to run DCALC, after which the design will develop quickly. You should prepare sketches showing: Bridge cross-section Deck plan Vertical Curve You will also need to collect other important to be included with your calculations: Geotechnical Borings and Recommendations Transmittals Survey Data Design References Typically, engineers draw hand sketches showing this information in their calculations. However, if CAD drawings are available, why not go directly to CAD? This decision will depend on the individual. We each approach things in our own way, and some may argue that jumping directly into CAD is juggling too many tasks at once. DCALC has a CAD interface, via DesignCAD. If you do not have a copy of DesignCAD, DCALC allows you to skip method. As the saying goes, There are many ways to skin a cat. So, here is a way to start: Draw a preliminary framing plan in CAD or a pencil sketch, such as the one shown below. Preliminary framing plan Typically, the horizontal alignment is developed by roadway engineers and is provided in AutoCAD or MicroStation format, and the structural engineer develops a framing plan, X-Referencing the roadway alignment files. AutoCAD and MicroStation drawings can easily be converted to DesignCAD, to be used by DCALC. However, it is not absolutely necessary to use DesignCAD. We will explain how to use DCALC with DesignCAD and also how to use it without DesignCAD. p.3-3

4 3.4. The Bridge Design FlowChart: After you start DCALC, you will see the main menu selection: Select Make a Calculation. Then select View Bridge Design Flowchart. You will then see the following screen: This flowchart shows the connectivity of DCALC s calculations used for designing bridges. The best way to design a bridge is to use a top down approach. (The same can p.3-4

5 be said for designing a building, in which case you begin by designing the roof, then work your way down to the foundation). You start with the deck, then the beams, then the bearings, then, finally the substructure. DCALC helps you follow this logic by having a bridge design flowchart, showing the sequence of the programs to be used Collecting Bridge Geometry Using DCBRIDGE: There is an example calculation located in C:\DCALC\DEMO, Example DCBRIDGE calculation Steel Bridge. The user should run this file to become familiar with the operations. DCBRIDGE is a little bit more involved than other DCALC calculations, and a step-by-step tutorial is included in the DesignCalcs website. There are two methods that can be used for entering geometry: Method 1 Manual Entry: If you do not have DesignCAD, you will be able to use DCBRIDGE. In fact, for simpler bridges, there is an alternative entry method that is about as fast as than using DesignCAD for entering points. Altenative entry involves the following steps: Defining the geometry of the station line Defining the parallel offset of each beam from the station line Defining the location of each pier/bearing using the station and angle with respect to the station line. Method 2 Using DesignCAD: If you have DesignCAD, you can use it to collect bridge geometrical information. There is elegance to this approach, since it avoids a duplication of effort. Essentially the idea is, if you ve already drawn the beam and lines accurately in CAD, why not use that information for design purposes? Interestingly, you can design an entire bridge from a CAD drawing, without computing any geometry (or loads)! This is a distinctively different approach than how engineers have worked in the past, when engineers did very difficult geometrical calculations. There can be an increase in efficiency and accuracy using the newer approach utilizing CAD in the right hands. It is important that engineers be able to check geometrical data independent of CAD. As we progress into the future, we need to recognize how previous engineers worked and what was good about the way they worked, and what was tedious and can be improved upon. 3.6 Defining Vertical Geometry Using ELEVS: Roadways and bridges alike have vertical geometry defined by a profile grade line, which is related to the horizontal geometry which is defined by the station line. We ve already defined the bridge horizontal geometry using DCBRIDGE, so now we need to define the bridge vertical geometry. Program ELEVS is used for this purpose. p.3-5

6 There is an example calculation in the C:\DCALC\DEMO directory, Example ELEVS calculation that was developed for this example. The reader should also run this calculation to try out the features. 3.7 Defining Bridge Loads Using LOADER: After you ve defined horizontal and vertical geometry, next is the process is the computation of loads. Program LOADER computes the beam loads that will be used by the beam design programs, for both steel and precast prestressed concrete beams. LOADER computes the dead load per unit length and the live load wheel distribution factor for each beam the traditional approach used by engineers to design bridge beams. It is an observation that this approach is in itself an approximation, since the true loads experienced by beams is dependent on the three dimensional characteristics of a bridge system, rather than line elements that we assume. LOADER computes live load distribution factors for both the AASHTO Standard Specifications and the LRFD Specifications. There is an example calculation in the C:\DCALC\DEMO directory, Example LOADER calculation Steel Bridge developed for this example. The reader should run this calculation to become familiar with the operation of this program. 3.8 Preliminary Sizing of Beams Using BRIJBEAM: Program BRIJBEAM is used design typical straight wide flange beams or plate girders. This is an iterative process: After defining horizontal geometry (DCBRIDGE) and vertical geometry (ELEVS), and loads (LOADER), define beam sizes using BRIJBEAM. You will need to make some assumptions here, so this is a guessing process. o Guess at a required wide flange size or plate girder size o Guess at splice locations After defining preliminary sizes, you will need to save this information in a beam file. Prepare input for the next program to be used, CBRIDGE. From the main menu, select Save CBRIDGE input. Exit BRIJBEAM. BRIJBEAM calculation. The user should also run this calculation to become familiar with the operation of this program. p.3-6

7 3.9 Computing Beam Moments and Shears Using CBRIDGE: Program CBRIDGE is used to compute moments and shears for typical straight beam type bridges. After starting CBRIDGE, when asked Is this a new or existing file, answer existing. Retrieve the CBRIDGE input file that you created using BRIJBEAM. Run it CBRIDGE calculation Steel Bridge. The user should also run this calculation to become familiar with the operation of this program Returning to BRIJBEAM to Design The Beams: Now you ve computed moments and shears using CBRIDGE, we can check if the beams that you sized are adequate. Start BRIJBEAM Retrieve Beam file (the beam data that you had previously guessed at) Retrieve CBRIDGE output (the moments and shears) Select Design A Span. For each span, you will see in a table the capacity of the member, and whether it is adequate ( OK ) or not ( NG ). Change the size of the beam as required to make the capacity adequate. After changing sizes as required, once again Save Beam File. Again, Save CBRIDGE input. Exit BRIJBEAM Go back to CBRIDGE and recomputed moments After one or two iterations, you will get a feel for the beam sizes that are required Design Splices using SPLICE: Continuous steel beam bridge have splices, usually located close to the points of dead load contraflexure. The usual practice is to locate the splices about 5 feet away from the dead load contraflexure point, to avoid placing the studs on the splice plates. SPLICE is used to design the splices. This program will use the output file from BRIJBEAM. Alternatively, the user can manually input design moments and shears. Again, this is an interative design process, where the engineer tries various bolts patterns and plate dimensions until a satisfactory splice capacity results. SPLICE calculation. The user should also run this calculation to become familiar with the operation of this program. p.3-7

8 3.12 Design Bearings using BEARINGS: DCALC has an automated bearing design program, based on the methods and practices used by the Illinois Department of Transportation. IDOT has standardized many of its bearing designs, based on typical bridge loadings and expansion lengths. For locations with high seismic forces, additional requirements may be required, beyond the capabilities of this program. The operation of this program is easy and self-explanatory Compute Deck Elevations using DECKELEV: The final shape of a bridge deck must fit the vertical profile specified for the roadway. Since all bridges deflect under the weight of the wet concrete, the concrete forms must be adjusted to compensate for the calculated deflection. For this purpose, bridge plans typically include deck elevation tables that show top of deck elevations adjusted for dead load deflection. Knowing the vertical profile and the beam deflections due to the weight of the wet concrete, the bridge engineer computes deck elevations using DECKELEV. This program automatically reads the vertical profile created by the ELEVS program and deflections computed from either BRIJBEAM (steel bridges) or PCBRIDGE (concrete bridges). Alternatively, the user can enter deflections computed by other methods. DECKELEV calculation. Also, there is a further write-up on deck elevations included in the Tutorials on the DesignCalcs website Compute Bearing Seat Elevations using BEAMELEV: The elevation of each bearing must be indicated in bridge plans. In order to calculate bearing seat elevations, the bridge engineer requires the following information: Vertical profile Fillet height (distance above beam/girder to bottom of deck) Beam depth Is the beam straight or cambered? Beam deflections Bearing heights This calculation can be especially complicated by hand, even using a spreadsheet. The BEAMELEV program computes bearing seat elevations, top of beam elevations and camber diagrams. If you have followed the flowchart, BEAMELEV will look for data previously computed by the other programs required for this calculation. BEAMELEV calculation Steel Bridge. p.3-8

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