Bridge Components and Elements
Bridge Components and Elements
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Table of Contents
Basic Concepts
Primer ..................................................................................................................................................
P.1-i
Basic Concepts Primer
TOPIC P.1: Bridge Components and Elements
P.1-ii
Topic P.1 Bridge Components and Elements
P.1.1
Introduction The bridge inspector should be familiar with the terminology and elementary
theory of bridge mechanics and materials. This topic presents the terminology
needed by inspectors to properly identify and describe the individual elements that
comprise a bridge. First the major components of a bridge are introduced. Then
the basic member shapes and connections of the bridge are presented. Finally, the
purpose and function of the major bridge components are described in detail.
P.1.2
NBIS Structure According to the Recording and Coding Guide for the Structure Inventory and
Appraisal of the Nation’s Bridges the minimum length for a structure carrying
Length traffic loads is 6.1meters (20 feet). The structure length is measured as shown on
Figure P.1.1
23 CFR Part 650.305 Definitions gives the definition of a bridge as it applies to the
NBIS regulations. From the NBIS regulations, a bridge is defined as follows: a
structure including supports erected over a depression or an obstruction, such as
water, highway, or railway, and having a track or passageway for carrying traffic
or other moving loads, and having an opening measured along the center of the
roadway of more than 20 feet between undercopings of abutments or spring lines
of arches, or extreme ends of openings for multiple boxes; it may also include
multiple pipes, where the clear distance between openings is less than half of the
smaller contiguous opening
P.1.3
Major Bridge A thorough and complete bridge inspection is dependent upon the bridge
inspector's ability to identify and understand the function of the major bridge
Components components and their elements. Most bridges can be divided into three basic parts
or components (see Figure P.1.1A):
¾ Deck
¾ Superstructure
¾ Substructure
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Deck
Superstructure
Pier (part of the
Abutment (part of substructure)
the substructure)
Timber Shapes Basic shapes, properties, gradings, deteriorations, protective systems, and
examination of timber are covered in detail in Topic 2.1.
Timber members are found in a variety of shapes (see Figure P.1.2). The sizes of
timber members are generally given in nominal dimensions (such as in Figures
P.1.2 and P.1.3). However, timber members are generally seasoned and surfaced
from the rough sawn condition, making the actual dimension about 13 to 20 mm
(1/2 to 3/4 inches) less than the nominal dimension.
The physical properties of timber enable it to resist both tensile and compressive
stresses. Therefore, it can function as an axially-loaded or bending member.
Timber bridge members are made into three basic shapes:
¾ Planks
¾ Beams
¾ Piles
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150 mm – 250 mm
300 mm
(6" - 10")
(12" dia.)
250 mm - 350 mm
300 mm
(10" - 14")
(12")
50 mm
(2")
Plank Pile Beam
Planks
Planks are most often used for bridge decks on bridges carrying light or infrequent
truck traffic. While some shapes and materials are relatively new, the use of
timber plank decks has existed for centuries. Timber planks are advantageous in
that they are economical, lightweight, readily available, and easy to erect.
Beams
Timber beams have more equal rectangular dimensions than do planks, and they
are sometimes square. Common dimensions include 250 mm by 250 mm (10
inches by 10 inches) square timbers, and 150 mm by 350 mm (6 inches by 14
inches) rectangular timbers.
Timbers can either be solid sawn or glued-laminated (see Figure P.1.3). Glued-
laminated timbers are advantageous in that they can be fabricated from smaller,
more readily available pieces. Glued lamination also allows larger rectangular
members to be formed without the presence of natural defects such as knots.
Glued-laminated timbers are normally manufactured from well-seasoned
laminations and display very little shrinkage after they are fabricated.
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Piles
Timber can also be used for piles. Piles are normally round, slender columns that
support the substructure footing or partially form the substructure. Piles may be
partially above ground or completely buried.
Concrete Shapes Basic ingredients, properties, reinforcement, deterioration, protective systems, and
examination of concrete are covered in detail in Topic 2.2.
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Concrete is a unique material for bridge members because it can be formed into an
infinite variety of shapes (see Figure P.1.4). Concrete members are used to carry
axial and bending loads. Since bending results in a combination of compressive
and tensile stresses, concrete bending members are typically reinforced with either
reinforcing steel (producing reinforced concrete) or with prestressing steel
(producing prestressed concrete) in order to carry the tensile stresses in the
member.
The most common shapes of reinforced concrete members are (see Figure P.1.5):
¾ Slabs/Decks
¾ Rectangular beams
¾ Tee beams
¾ Channel beams
Bridges utilizing these shapes and mild steel reinforcement have been constructed
and were typically cast-in-place (CIP). Many of the designs are obsolete, but the
structures remain in service. Concrete members of this type are used for short and
medium span bridges.
Slab/Deck
Channel
Tee
Rectangular
Figure P.1.5 Reinforced Concrete Shapes
Concrete slabs are used for concrete decks and slab bridges. On concrete decks,
the concrete spans the distance between superstructure members and is generally
180 to 230 mm (7 to 9 inches) thick. On slab bridges, the slab spans the distance
between piers or abutments, forming an integral deck and superstructure. Slab
bridge elements are usually 300 to 600 mm (12 to 24 inches) thick.
Rectangular beams are used for both superstructure and substructure bridge
elements. Concrete pier caps are commonly rectangular beams which support the
superstructure.
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I-Beam Bulb-tee
Box Beam
Voided Slab
Box Girder
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Reinforced Prestressed
Figure P.1.7 Mild Steel Reinforced Concrete vs. Precast Prestressed Concrete
I-beams, distinguished by their "I" shape, function as superstructure members and
support the deck. This type of beam can be used for spans as long as 46 m (150
feet).
Bulb-tee beams are distinguished by their "T" shapes, with a bulb-shaped section
(similar to the bottom flange of an I-beam) at the bottom of the vertical leg of the
tee. This type of beam can be used for spans as long as 55 m (180 feet).
Voided slabs, distinguished by their rectangular shape and their interior voids, are
generally precast units supported by the substructure. The interior voids are used
to reduce the dead load. Voided slabs can be used for spans of 9 to 24 m (30 to
80 feet).
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Concrete axially-loaded compression members are used in bridges in the form of:
¾ Columns
¾ Arches
¾ Piles
Because these members also carry varying bending forces, they contain steel
reinforcement.
Columns are straight members which can carry axial load, horizontal load, and
bending and are used as substructure elements. Columns are commonly square,
rectangular, or round.
Piles are slender columns that support the substructure footing or partially form
the substructure. Piles may be partially above ground but are usually completely
buried (see Figure P.1.8).
Iron Shapes Iron was used predominately as a bridge material between 1850 and 1900.
Stronger and more fire resistant than wood, iron was widely used to carry the
expanding railroad system during this period.
There are two types of iron members: cast iron and wrought iron. Cast iron is
formed by casting, whereas wrought iron is formed by forging or rolling the iron
into the desired form.
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Cast Iron
Historically, cast iron preceded wrought iron as a bridge material. The method of
casting molten iron to form a desired shape was more direct than that of wrought
iron.
Casting allowed iron to be formed into almost any shape. However, because of
cast iron's brittleness and low tensile strength, bridge members of cast iron were
best used to carry axial compression loads. Therefore, cast iron members were
usually cylindrical or box-shaped to efficiently resist axial loads.
Wrought Iron
In the late 1800's, wrought iron virtually replaced the use of cast iron. The two
primary reasons for this were that wrought iron was better suited to carry tensile
loads and advances in rolling technology made wrought iron shapes easier to
obtain and more economical to use. Advances in technology made it possible to
form a variety of shapes by rolling, including:
¾ Rods and wire
¾ Bars
¾ Plates
¾ Angles
¾ Channels
¾ Beams
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Steel Shapes Steel bridge members began to be used in the United States in the late 1800’s and,
by 1900, had virtually replaced iron as a bridge material. The replacement of iron
by steel was the result of advances in steel making (see Figure P.1.9). These
advances yielded a steel material that surpassed iron in both strength and
elasticity. Steel could carry heavier loads and better withstand the shock and
vibration of ever-increasing live loads. Since the early 1900’s, the quality of steel
has continued to improve. Stronger and more ductile A36, A572, and A588 steels
have replaced early grades of steel, such as A7.
Due to their strength, steel bridge members are used to carry axial forces as well as
bending forces. Steel shapes are generally either rolled or built-up.
Rolled Shapes
Rolled steel shapes commonly used on bridges include (see Figure P.1.10):
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I-beams and
Channels
The standard weights and dimensions of these shapes can be found in the
American Institute of Steel Construction (AISC) Manual of Steel Construction.
Bars and plates are formed into flat pieces of steel. Bars are normally considered
to be up to 200 mm (8 inches) in width. Common examples of bars include lacing
bars on a truss and steel eyebars. Plates are designated as flat plates if they are
over 200 mm (8 inches) in width. A common example of a plate is the gusset plate
on a truss. Bars and plates are dimensioned as follows: width x thickness x length.
Examples of bar and plate dimensions include:
Angles are “L”-shaped members, the sides of which are called “legs”. Each angle
has two legs, and the width of the legs can either be equal or unequal. When
dimensioning angles, the two leg widths are given first, followed by the thickness
and the length. Examples of angle dimensions include:
Angles, bars, and plates are commonly connected to form bracing members (see
Figure P.1.11).
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Figure P.1.11 Bracing Members Made from Angles, Bars, and Plates
Channels are squared-off "C"-shaped members and are used as diaphragms, struts,
or other built-up members. The top and bottom parts of a channel are called the
flanges. Channels are dimensioned by the depth (the distance between outside
edges of the flanges) in mm or inches, the weight in kg per m or pounds per foot,
and the length in mm or inches. Examples of channel dimensions include:
¾ C 230 x 22 x 2895 mm (C 9 x 15 x 9'-6")
¾ C 310 x 31 x 3416 mm (C 12 x 20.7 x 11'-2-1/2")
When measuring a channel, it is not possible for the inspector to know how much
the channel section weighs. In order to determine the weight, the inspector must
record the flange width and the web depth. From this information, the inspector
can then determine the true channel designation through the use of reference
books.
Beams are “I”-shaped sections used as main load-carrying members. The load-
carrying capacity generally increases as the member size increases. The early days
of the iron and steel industry saw the various manufacturers rolling beams to their
own standards. It was not until 1896 that beam weights and dimensions were
standardized when the Association of American Steel Manufacturers adopted the
American Standard beam. Because of this, I-beams are referred to by many
designations, depending on their dimensions and the time period in which the
particular shape was rolled. Today all I-beams are dimensioned according to their
depth, weight, and length.
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Built-up Shapes
The practice of riveting steel shapes began in the 1800’s and continued through the
1950’s. Typical riveted shapes include girders and boxes.
Riveted girders are large I-beam members fabricated from plates and angles.
These girders were fabricated when the largest rolled beams were still not large
enough as required by design (see Figure P.1.12).
Riveted boxes are large rectangular shapes fabricated from plates, angles, or
channels. These boxes are used for cross-girders, truss chord members, and
substructure members (see Figure P.1.13).
As technology improved, the need for riveting was replaced by high strength bolts
and welding. Popular since the early 1960's, welded steel shapes also include
girders and boxes.
Welded girders are large I-beam members fabricated from plates. They are
referred to as welded plate girders and have replaced the riveted girder (see Figure
P.1.14).
Welded boxes are commonly used for superstructure girders, truss members, and
cross girders. Welded box shapes have replaced riveted box shapes (see Figure
P.1.15).
top flange
cover plate
web plate
flange
angle
bottom flange
cover plate
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top flange
web plate
bottom flange
Cables
Steel cables are tension members and are used in suspension, tied-arch, and cable-
stayed bridges. They are used as main cables and hangers of these bridge types
(see Figure P.1.16). Refer to Topic 12.1 for a more detailed description of cable-
supported bridges.
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P.1.5
Connections Rolled and built-up steel shapes are used to make stringers, floor beams, girders,
and truss members. These members require structural joints, or connections, to
transfer loads between members. There are several different types of bridge
member connections:
¾ Pin connections
¾ Riveted connections
¾ Bolted connections
¾ Welded connections
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Pin Connections Pins are cylindrical beams produced by forging, casting, or cold-rolling. The pin
sizes and configurations are as follows (see Figure P.1.17):
¾ A small pin, 32 to 100 mm (1-1/4 to 4 inches) in diameter, is usually
made with a cotter pin hole at one or both ends
¾ A medium pin, up to 250 mm (10 inches) in diameter, usually has
threaded end projections for recessed retainer nuts
¾ A large pin, over 250 mm (10 inches) in diameter, is held in place by a
recessed cap at each end and is secured by a bolt passing completely
through the caps and pin
Pins are often surrounded by a protective sleeve, which may also act as a spacer
to separate members. Pin connections are commonly used in eyebar trusses,
hinged arches, pin and hanger assemblies, and bearing supports (see Figure
P.1.18).
SMALL PIN
COTTER
MEDIUM PIN
BOLT
LARGE PIN
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The major advantages of using pin connection details are the design simplicity
and the ability for free end rotation. The design simplicity afforded by pin
connections reduces the amount and complexity of design calculations. By
allowing for free end rotation, pin connections reduce the level of stress in the
member.
The major disadvantages of pin connection details are the result of vibration, pin
wear, unequal eyebar tension, unseen corrosion, and poor inspectability.
Vibrations increase with pin connections because they allow more movement than
more rigid types of connections. As a result of increased vibration, moving parts
are subject to wear.
Pin connections are used both in trusses and at expansion joints. Both truss and
girder suspended spans or cantilever joints that permit expansion are susceptible
to freezing or fixity of the pinned joints. This results in changes in the structure
and undesirable stresses when axially-loaded members become bending members.
Some pins connect multiple eyebars. Since the eyebars may have different
lengths, they may experience different levels of tension. In addition, because
parts of the pin surface are hidden from view by the eyebars, links, or connected
parts, an alternate method of completely inspecting the pin must be used (e.g.,
ultrasonic or pin removal).
Riveted Connections The rivet was the primary fastener used in the early days of iron and steel bridges.
The use of high strength bolts replaced rivets by the early 1960’s.
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High Button
Flat Head
Counter Sunk
The rivet sizes most often used on bridges were 19, 23, or 25 mm (3/4, 7/8, or 1-
inch) shank diameters. Rivet holes were generally 2 mm (1/16-inch) larger than
the rivet shank. While the hot rivet was being driven, the shank would increase
slightly, filling the hole. As the rivet cooled, it would shrink in length, clamping
together the connected elements.
When the inspector can feel vibration on one head of the rivet while hitting the
other rivet head with a hammer, this generally indicates that the rivet is loose.
This method may not work with sheared rivets clamped between several plates.
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Bolted Connections Research into the use of high strength bolts began in 1947. The first
specifications for the use of bolts were subsequently published in 1951. The
economic and structural advantages of bolts over rivets led to their rapid use by
bridge engineers. Bridges constructed in the late 1950’s may have a combination
of riveted (shop) and bolted (field) connections (see Figure P.1.20).
For further information on the bolts listed above or any other material properties
visit the American Society for Testing and Materials International website at:
www.astm.org .
The inspector must be cautioned that standard tables and formulas relating tension
to torque are no longer considered valid.
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Simple techniques, such as looking and feeling for loose bolts, are the most
common methods used by inspectors when inspecting bolts.
Welded Connections Pins, rivets, and bolts are examples of mechanical fasteners forming non-rigid
joints. A welded connection is not mechanical but rather is rigid one-piece
construction. A properly welded joint, in which two pieces are fused together, is
as strong as the joined materials.
The first specification for using welds on bridges appeared in 1936. Welding
eventually replaced rivets for fabricating built-up members. Welded plate girders,
hollow box-like truss members, and shear connectors for composite decks are just
a few of the advances attributed to welding technology.
Welds need to be carefully inspected for cracks or signs of cracks (e.g., broken
paint or rust stains) in both the welds and the adjoining base metal elements.
Pin and Hanger A pin and hanger connection is a type of hinge consisting of two pins and a
Connections hanger. Pin and hanger connections are used in an articulated (continuous bridge
with hinges) or a suspended span configuration. The location of the connection
varies depending on the type of bridge. In I-beam bridges, a hanger is located on
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either side of the webs (see Figure P.1.22). In suspended span truss bridges, each
connection has a hanger which is similar in shape to the other truss members
(with the exception of the pinned ends).
Pin and hanger connections must be carefully inspected for signs of wear and
corrosion. A potential problem can occur if corrosion of the pin and hanger
causes the connection to "freeze," inhibiting free rotation. This condition does
not allow the pin to rotate and results in additional stresses in the pin and hanger
and adjacent girder. The failure of a pin and hanger connection can cause a
partial or complete failure of the bridge.
Splice Connections A splice connection is the joining of two sections of the same member, either in
the fabrication shop or in the field. This type of connection can be made using
rivets, bolts, or welds. Bolted splices are common in multi-beam superstructures
due to the limited allowable shipping lengths (see Figure P.1.23). Welded flange
splices are common in large welded plate girders as a means of fabricating the
most economical section.
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Deck Purpose The purpose of the deck is to provide a smooth and safe riding surface for the
traffic utilizing the bridge (see Figure P.1.24).
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Deck Function The function of the deck is to transfer the live load and dead load of the deck to
other bridge components. In most bridges, the deck distributes the live load to the
superstructure (see Figure P.1.25). However, on some bridges (e.g., a concrete
slab bridge), the deck and superstructure are one unit which distributes the live
load directly to the bridge supports.
Wearing Surface
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Figure P.1.27 Shear Studs on Top Flange of Girder (before Concrete Deck is
Placed)
Deck Materials There are three common materials used in the construction of bridge decks:
¾ Timber
¾ Concrete
¾ Steel
Timber Decks
Timber decks are normally referred to as decking or timber flooring, and the term
is limited to the roadway portion which receives vehicular loads. Refer to Topic
5.1 for a detailed explanation on the inspection and evaluation of timber decks.
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Concrete Decks
Concrete permits casting in various shapes and sizes and has provided the bridge
designer and the bridge builder with a variety of construction methods. Because
concrete is weak in tension, it is used together with reinforcement to resist the
tensile stresses (see Figure P.1.29). Refer to Topic 5.2 for a detailed explanation
on the inspection and evaluation of concrete decks.
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Steel Decks
Steel decks are decks composed of either solid steel plate or steel grids (see Figure
P.1.30). Refer to Topic 5.3 for a detailed explanation on the inspection and
evaluation of steel decks.
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Wearing Surfaces
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¾ Open joints
¾ Closed joints
Open Joints
Open joints allow water and debris to pass through them. There are two types of
unsealed joints:
¾ Formed joints
¾ Finger plate joints (see Figure P.1.33)
Closed joints are designed so water and debris do not pass through them. There
are seven types of closed joints:
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Extrusion
Strip
Seal
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Drainage Systems
The primary function of a drainage system is to remove water from the bridge
deck, from under unsealed deck joints and from behind abutments and wingwalls.
¾ Deck drains
¾ Outlet pipes - to lead water away from drain
¾ Downspouts pipes - to transport runoff to storm sewers
¾ Cleanout plugs - for maintenance
Combining all these drainage components forms a complete deck drainage system.
Deck Appurtenances
The proper and effective use of deck appurtenances minimizes hazards for traffic
on the highways as well as waterways beneath the bridge.
Bridge Barriers
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The function of sidewalks and curbs is to provide access to and maintain safety for
pedestrians. Curbs serve to lessen the chance of vehicles crossing onto the
sidewalk and endangering pedestrians.
Signing
Signing serves to inform the motorist about bridge or roadway conditions that may
be hazardous.
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Refer to Topic 5.4 for a more detailed explanation on joints, drainage, signing, and
lighting of bridge decks. Refer to Topic 5.5 for a more detailed explanation on
safety features and barriers of bridge decks.
P.1.7
Superstructure
Superstructure Purpose The basic purpose of the superstructure is to carry loads from the deck across the
span and to the bridge supports. The superstructure is that component of the bridge
which supports the deck or riding surface of the bridge, as well as the loads
applied to the deck.
Superstructure Function The function of the superstructure is to transmit loads. Bridges are named for their
type of superstructure. Superstructures may be characterized with regard to their
function (i.e., how they transmit loads to the substructure). Loads may be
transmitted through tension, compression, bending, or a combination of these
three.
¾ Timber
¾ Concrete
¾ Steel
¾ Floor system - Receives traffic loads from the deck and distributes them to
the main supporting elements (see Figure P.1.39)
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¾ Main supporting elements - Transfer all loads to the substructure units (see
Figure P.1.40)
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Beam Arch
Cable Supported
Figure P.1.44 Three Basic Bridge Types
Beam Bridges
In the case of beam bridges, loads from the superstructure are transmitted
vertically to the substructure. Examples of beam bridges include:
¾ Slabs (concrete) (see Figure P.1.45)
¾ Beams (timber, concrete, or steel) (see Figures P.1.46, P.1.50, P.1.51)
¾ Girders (concrete or steel) (see Figures P.1.47, P.1.48, P.1.49, P.1.52)
¾ Trusses (timber or steel) (see Figures P.1.53 and P.1.54)
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In the case of arch bridges, the loads from the superstructure are transmitted
diagonally to the substructure. True arches are in pure compression. Arch bridges
can be constructed from timber, concrete, or steel (see Figures P.1.55 and P.1.56).
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P.1.44
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Movable Bridge
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P.1.46
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Floating Bridges
Although uncommon, some states have bridges that are not supported by a
substructure. Instead, they are supported by water. The elevation of the bridge will
change as the water level fluctuates.
Culverts
Culverts are often viewed as small bridges, being constructed entirely below and
independent of the roadway surface. However, culverts do not have a deck,
superstructure, or substructure (see Figure P.1.63). Refer to Topics P.3, 12.3 and
12.4 for a more detailed explanation on culverts.
Basic Elements A bridge bearing can be broken down into four basic elements (see Figure P.1.64):
¾ Sole plate
¾ Masonry plate
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Sole Plate
Bearing
Masonry Device
Plate
Anchorage
P.1.9
Substructure The substructure is the component of a bridge which includes all the elements
which support the superstructure.
Substructure Purposes The purpose of the substructure is to transfer the loads from the superstructure to
the foundation soil or rock. Typically the substructure includes all elements below
the bearings. The loads are then distributed to the earth through the footing.
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Substructure Function Substructure units function as both axially-loaded and bending members. These
units resist both vertical and horizontal loads applied from the superstructure and
roadway embankment. Substructures are divided into two basic categories:
¾ Abutments
¾ Piers and bents
Abutments provide support for the ends of the superstructure and retain the
roadway approach embankment (see Figure P.1.65). Piers and bents provide
support for the superstructure at intermediate points along the bridge spans with a
minimum obstruction to the flow of traffic or water (see Figure P.1.66).
P.1.50
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
¾ Cantilever or full height abutment - extends from the grade line of the
roadway or waterway below, to that of the road overhead (see Figure
P.1.67).
¾ Stub, semi-stub, or shelf abutment - located within the topmost portion of
the end of an embankment or slope. In the case of a stub, less of the
abutment stem is visible than in the case of the full height abutment.
Most new construction uses this type of abutment. These abutments may
be required to be supported on deep foundations (see Figure P.1.68).
¾ Spill-through or open abutment - consists of columns and has no solid
wall, but rather is open to the embankment material. The approach
embankment material is usually rock (see Figure P.1.69).
bridge seat
backwall
abut. backwall
abutment stem stem
wing footing
footing
P.1.51
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
bridge seat
backwall
backwall
wing abut.
abutment stem stem
footing
footing
bridge seat
backwall
backwall
cap beam
floating cap
wingwall beam
column column
footing
footing
A pier has only one footing at each substructure unit (the footing may serve as a
pile cap). A bent has several footings or no footing, as is the case with a pile bent.
Refer to Topic 10.2 for a more detailed explanation on bridge piers and bents.
P.1.52
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
P.1.53
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
P.1.54
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
P.1.55
SECTION P: Basics Concepts Primer
Topic P.1: Bridge Components and Elements
P.1.56