Structural Design Manual: ALDOT Bridge Bureau

Structural Design
Manual
ALDOT Bridge Bureau

February 2019
THIS PAGE INTENTIONALLY LEFT BLANK
ALDOT Structural Design Manual
TABLE OF CONTENTS
PREFACE ----------------------------------------------------------------------------------- v
I. ALDOT Policy Statement ---------------------------------------------------- v

II. Purpose and Scope of this Manual --------------------------------------- v
III. Design Method/Specifications -------------------------------------------- vi
IV. Related Manuals ------------------------------------------------------------- vi
V. Approval ------------------------------------------------------------------------ vi
SECTION 1. INTRODUCTION -------------------------------------------------------- 1-1
SECTION 2. GENERAL DESIGN AND LOCATION FEATURES ------------2-1
2.1 Deformations ----------------------------------------------------------------- 2-1

2.2 Clearances -------------------------------------------------------------------- 2-1
2.3 Drainage ----------------------------------------------------------------------- 2-1
SECTION 3. LOADS AND LOAD FACTORS ------------------------------------- 3-1
3.1 Permanent Loads ----------------------------------------------------------- 3-1

3.2 Water and Wind Loads ---------------------------------------------------- 3-1
3.3 Temperature Force Effects ----------------------------------------------- 3-1
SECTION 4. STRUCTURAL ANALYSIS AND EVALUATION --------------- 4-1
SECTION 5. CONCRETE STRUCTURES ----------------------------------------- 5-1
5.1 Concrete Compressive Strengths --------------------------------------- 5-1

5.2 Prestressed Concrete Girder Design Policy -------------------------- 5-2
5.3 Superstructure Intermediate Diaphragms ----------------------------- 5-4
5.4 Steel Reinforcement -------------------------------------------------------- 5-4
SECTION 6. STEEL STRUCTURES ------------------------------------------------ 6-1
6.1 Materials ----------------------------------------------------------------------- 6-1

6.2 Girder Design Policy --------------------------------------------------------6-1
6.3 Shear Connectors ----------------------------------------------------------- 6-3
6.4 Shop Connections ---------------------------------------------------------- 6-3
6.5 Field Connections ----------------------------------------------------------- 6-4
February 2019 i
SECTION 7. ALUMINUM STRUCTURES ------------------------------------------ 7-1
SECTION 8. WOOD STRUCTURES ------------------------------------------------ 8-1
SECTION 9. DECKS AND DECK SYSTEMS ------------------------------------- 9-1
9.1 Reinforced Concrete Decks ---------------------------------------------- 9-1

9.2 Incremental Deck Finish Grade Elevations --------------------------- 9-3
SECTION 10. FOUNDATIONS -------------------------------------------------------- 10-1
10.1 Substructure Types ------------------------------------------------------- 10-1

10.2 Pile Footings-Scour Considerations ---------------------------------- 10-1
10.3 Foundation Piling ---------------------------------------------------------- 10-2
10.4 Geotechnical Coordination ---------------------------------------------- 10-3
SECTION 11. WALLS, ABUTMENTS AND PIERS ----------------------------- 11-1
11.1 Abutments, Bents, Piers ------------------------------------------------- 11-1

11.2 Retaining Walls ------------------------------------------------------------ 11-1
SECTION 12. BURIED STRUCTURES AND TUNNEL LINERS ------------- 12-1
12.1 Reinforced Concrete Box Culverts ------------------------------------ 12-1
SECTION 13. RAILINGS --------------------------------------------------------------- 13-1
13.1 Bridge Railings ------------------------------------------------------------- 13-1
SECTION 14. JOINTS AND BEARINGS ------------------------------------------- 14-1
14.1 Expansion Joints -----------------------------------------------------------14-1

14.2 Bearing Devices ----------------------------------------------------------- 14-1
14.3 Anchor Bolts ---------------------------------------------------------------- 14-1
SECTION 15. DESIGN OF SOUND BARRIERS --------------------------------- 15-1
SECTION 16. BRIDGE RATING ------------------------------------------------------ 16-1
SECTION 17. STRUCTURES FOR TRAFFIC CONTROL DEVICES

AND HIGHWAY LIGHTING ---------------------------------------------------- 17-1
SECTION 18. PRECAST BRIDGES ------------------------------------------------- 18-1
February 2019 ii
APPENDIX A. PROCEDURE FOR PROPOSING REVISIONS TO THE

DESIGN MANUAL --------------------------------------------------------------- A-1
APPENDIX B. RECORD OF REVISIONS ------------------------------------------ B-1
END OF DOCUMENT
February 2019 iii

February 2019 iv
PREFACE
I. ALDOT POLICY STATEMENT
All bridge and miscellaneous transportation structures in Alabama shall be

designed in accordance the ALDOT Structures Design Manual except as
noted herein.
II. PURPOSE AND SCOPE
This manual contains specific design criteria policies mandated by the

ALDOT Bridge Bureau applying equally to ALDOT as well as consultants
completing structural designs. The primary purpose of this manual is:
• To provide interpretation and consistency in the application of the

AASHTO LRFD Bridge Design Specifications.
• To encourage the uniform preparation of plans and specifications.
• To provide direction to be followed on projects under the authority or

oversight of the Bridge Bureau, unless exceptions are approved by the
State Bridge Engineer.
Exceptions, based on sound engineering principles and judgment, are

expected. Structural plans and specifications must clearly communicate the
design intent and construction requirements of each project. This manual is
targeted for internal Bridge Bureau use; however, Consultants preparing
designs for projects to be let through ALDOT are expected to follow the
directives noted herein.
The contents of this manual generally follow the section headings of the
AASHTO LRFD Bridge Design Specifications. ALDOT exceptions to specific
requirements of the AASHTO LRFD Bridge Design Specifications are
indicated as follows:
ALDOT exception to AASHTO:
A description of the ALDOT exception is given here.
This manual will be continually updated as revisions and improvements are

warranted. Any questions, comments, concerns, and/or suggestions are
welcomed and should be submitted to:
February 2019 v
William T. Colquett, P.E.

State Bridge Engineer
Alabama Department of Transportation
1409 Coliseum Blvd., Rm. U201
Montgomery, AL 36130-3050
[email protected]
III. DESIGN METHOD/SPECIFICATIONS
All bridge and miscellaneous transportation structures in Alabama shall be

designed using Load and Resistance Factor Design (LRFD), unless otherwise
directed by the State Bridge Engineer. The governing design specification for
all bridges and miscellaneous transportation structures in Alabama shall be
the AASHTO LRFD Bridge Design Specifications, Eighth Edition, applicable
Interims along with any notations and exceptions indicated herein. Within this
manual, the AASHTO LRFD Bridge Design Specifications is referred to as
AASHTO LRFD. Other AASHTO Specifications, Guide Specifications and the
ALDOT Standard Specifications shall also apply as appropriate.
Consultant prepared designs, whether prepared directly for the Bridge Bureau
or any other office in the Department, shall be submitted according to the
requirements given in the Administrative Code of the Board of Registration for
Professional Engineers and Land Surveyors, Chapter 330-X-11-.03.
IV. RELATED ALDOT MANUALS/DOCUMENTS
Other documents maintained and/or used by the ALDOT Bridge Bureau

include the following:
• Bridge Plan Development QC/QA Plan and Checklist
• ALDOT Guide for Developing Construction Plans
• Bridge Special Project Drawings
• ALDOT Standard Specifications for Highway Construction
• ALDOT Special and Standard Highway Drawings
• Quality Control Manual for Bridge Plan Detailing
• Guide to Developing Bridge Plans
• ALDOT Guidelines for Operation
February 2019 vi
February 2019 viii

SECTION 1. INTRODUCTION
The requirements of the AASHTO LRFD Section 1 shall apply to this section
unless noted and/or excepted below.
1.1 LIMIT STATES
The value of the load modifier, ηi (see AASHTO LRFD Article 1.3.2.1) and its
factors, ηD, ηR, and ηI, shall all be set equal to 1.00, unless otherwise directed
by the State Bridge Engineer.
February 2019 1-1

February 2019 1-2

SECTION 2. GENERAL DESIGN AND LOCATION FEATURES
The requirements of the AASHTO LRFD Section 2 shall apply to this section
unless noted and/or excepted below.
2.1 DEFORMATIONS
Criteria for deflection is presented in AASHTO LRFD Article 2.5.2.6.2.
Live load deflection shall be checked for both loading options as given in
AASHTO LRFD Section 3.6.1.3.2
2.2 CLEARANCES
Criteria for highway vertical and horizontal clearances is presented in

AASHTO LRFD Articles 2.3.3.2 and 2.3.3.3 respectively.
Horizontal and vertical clearances for Highway Grade Separation structures shall
conform to ALDOT Guidelines for Operation Sections 3-25 Bridges Vertical
Clearance and 3-76 Bent or Pier Placement Criteria for Proposed Bridges
Overpassing Multilane Roadways
2.3 DRAINAGE
Criteria for the Design Storm is presented in AASHTO Article 2.6.6.2.
The design storm shall be the 10 year recurrence except where the low point of a
sag vertical curve exists on the bridge wherein the 50 year recurrence shall be
used. Exceptions to this policy shall have the prior approval of the Bridge
Engineer.
Criteria for deck drains is presented in AASHTO Articles 2.6.6.3 and 2.6.6.4.
February 2019 2-1

Bridge deck drainage shall be allowed to fall freely to the ground through deck
scuppers unless otherwise directed by the Bridge Engineer. Four inch diameter
scuppers spaced on five foot center (maximum) shall provide deck drainage for a
normal crowned section with eight to ten foot shoulders. In a super elevated
section, four inch diameter scuppers on four foot centers shall be used unless
hydraulic calculations indicate that different scuppers and / or spacing is
required. Scuppers shall be omitted over pier caps, roadway lanes, and railroad
right-of-way. Larger scuppers or deck drain inlets may be required if the above
design is not adequate or if a closed system is required.
February 2019 2-2

SECTION 3. LOADS AND LOAD FACTORS

The requirements of AASHTO LRFD Section 3 shall apply to this section unless
noted and/or excepted below.
3.1 PERMANENT LOADS
The following loads shall be used:
• Metal stay-in-place forms for bridge decks (as applicable) – Allow 15 psf dead
load (this includes the dead weight concrete in the forms).
• Barrier rail load – The barrier rail dead load shall be considered equally
distributed across all girders. However, the dead load for girder design shall not
be less than 25% of a single barrier rail weight.
3.2 WATER AND WIND LOADS
• Bridges exposed to coastal influences shall be designed in accordance with the

latest AASHTO Guide Specifications for Bridges Vulnerable to Coastal Storms.
3.3 TEMPERATURE FORCE EFFECTS
• Thermal baseline shall be set at 70º F.
February 2019 3-1

February 2019 3-2

SECTION 4. STRUCTURAL ANALYSIS AND EVALUATION
The methods of analysis described in AASHTO LRFD Section 4 shall apply to this
section unless noted and/or excepted below.
ALDOT has no analysis and evaluation considerations beyond those covered in the
AASHTO LRFD Bridge Design Specifications.
February 2019 4-1

February 2019 4-2

SECTION 5. CONCRETE STRUCTURES

The provisions of AASHTO LRFD Section 5 shall apply to this section unless
5.1 CONCRETE COMPRESSIVE STRENGTHS
• Reinforced Concrete:
Designers shall refer to the current edition of the ALDOT Standard Specifications
for strengths to be used in different structures. Plan sheets of various structural
members shall list the concrete strength for that member.
Superstructure (including barrier rails and deck) and substructure (including

footings [except as noted below] and drilled shafts) concrete strength (f’c)
shall be 4.0 ksi.
Retaining wall and cast-in-place box culvert concrete strength (f’c) shall be 4.0
ksi.
Seal footing and miscellaneous drainage structure concrete strength (f’c) shall
be 3.0 ksi
Greater concrete strengths may be utilized when required by design, subject to

prior approval by the State Bridge Engineer, and shall be noted accordingly on
the contract drawings.
• Prestressed Concrete:
The following values of f’c shall be used for these structures:
Bridge Component f’c (ksi)
Piles 5.0 to 6.0
Girders 5.0 to 8.0*
Table 5-1
* Higher strengths will require prior approval by the State Bridge Engineer
For prestressed concrete members, specific concrete strengths used for design
and specified for fabrication shall be stated on the contract drawings.
February 2019 5-1

5.2 PRESTRESSED CONCRETE GIRDER DESIGN POLICY
The following policies shall be used for the design of prestressed concrete girders:
1. The following standard shape AASHTO-PCI type girders are preferred:

Type I, Type II, Type III, BT-54, BT-63, and BT-72, as well as solid and
voided slab beams. Modifications of these girders or other girder types may
be proposed for use in special circumstances and shall have the approval of
the State Bridge Engineer prior to implementation.
2. Girders shall be designed as simple spans for all dead and live loads. Spans
shall not be made continuous for live load. To eliminate joints, decks may be
made continuous (link slabs).
3. The transformed area of bonded reinforcement shall not be included in the

calculations of section properties for prestressed concrete girders.
4. Pretensioning strands shall be 0.5 or 0.6 inches in diameter, low relaxation,

270 ksi Ultimate Tensile Strength. Use strand areas as follows:
a. For 0.5” dia. low relaxation strand, use A = 0.153 sq. inches
b. For special 0.5” dia. low relaxation strand, use A = 0.167 sq. inches
c. For 0.6” dia. low relaxation strand, use A = 0.217 sq. inches
5. Girders shall be designed so that no tension occurs in the bottom of the girder
after losses under the Service III load combination limit state. In no case shall
tension in Service III conditions exceed 0.0948√f’c (ksi). Exceptions to this
policy shall require prior approval of the State Bridge Engineer.
6. Girder shear steel reinforcement shall not be spaced greater than 18 inches
on center. Shear steel reinforcement in the girder ends shall be spaced 4
inches on center and shall extend from the end of the girder for a distance
equal to the girder depth. Shear steel reinforcement shall be spaced so that
no additional reinforcement is necessary to address horizontal shear forces at
the top of the girder. Confinement steel reinforcement shall be #3 spaced at
4” and shall extend from the end of the girder for a distance equal to the
beam depth. Vertical shear steel reinforcement shall be no smaller than #5.
Shear steel reinforcement shall extend above the top of the girder to engage
the slab at approximate mid-depth with a standard 90º hook.
7. Calculation of camber due to prestress prior to pouring the bridge deck shall
be based on a 60-day interval between release of the strand and erection of
the girder.
8. Debonding of prestressed concrete girders shall be as given in AASHTO

LRFD Section 5.11.4.3.
February 2019 5-2
9. For calculating losses, use the AASHTO LRFD Approximate Method,

neglecting gains. The following values shall be used for calculating losses:
• Time at release: 0.75 days
• Age of deck placement: 60 days
• Final age: 27,500 days
• Relative Humidity: 75%
10. Section 5.10.10.1 – Splitting Resistance, of the AASHTO LRFD Section,

Pretensioned Anchorage Zones, has the following paragraph:
“The resistance shall not be less than four percent of the total prestressing
force at transfer”
ALDOT defines, “...force at transfer”, to be the stress inducing force in the

girder end at release.
11. For purposes of mitigating horizontal cracking in girder webs at the ends,
draped strands should have an angle of incidence no larger than 1.75
degrees from horizontal along with de-bonding of straight strands. (Research
has indicated that horizontal cracking in the web of bulb tees at girder ends
results from tensile stresses induced by moments created by forces from both
draped and straight strands. It suggests, to the largest extent possible,
lowering the drape angle below that noted above along with de-bonding the
straight strands. It also recommended dropping the usual practice of including
short horizontal bars in the webs (for ALDOT known as M bars) as they are of
little value in mitigating the cracking issue.)
12. The following shall be shown on the prestress camber diagram for the ends of
the prestressed concrete girder:
• Girder depth
• Haunch thickness
• Deck thickness
• Total deck plus haunch thickness
• Theoretical camber
• Dead load deflection
The reporting format for this information is graphically presented in the Quality
Control Manual for Bridge Plan Detailing.
February 2019 5-3
13. A minimum one inch haunch shall be provided at girder mid-span, calculated
at the critical edge of the girder flange. Minimum buildup at girder ends shall
take into consideration vertical curve, superelevation transition, or other
complex roadway geometry. The build-up should be investigated for each
girder line and adjusted as necessary.
5.3 INTERMEDIATE DIAPHRAGMS
For concrete girders, intermediate diaphragms shall be used only when required by
calculation and shall be concrete.
5.4 STEEL REINFORCEMENT
Steel grade shall be as stated in the ALDOT Standard Specifications and shall also
be stated on bridge plan sheets where reinforcing steel is called for.
The following design clearances (concrete cover) shall be used for reinforced
concrete structures: See Section 3.3.3 of the Quality Control Manual for Bridge Plan
Detailing.
The following reinforcing steel spacing requirements shall be satisfied:
1. Criteria for minimum and maximum spacing of reinforcement shall be in

accordance with AASHTO LRFD Article 5.10.3.
The maximum spacing of flexural reinforcement shall not exceed 9 inches.
2. Where flexural reinforcement is placed in two or more layers, bars in the upper
layers shall be placed directly above the bottom layer with layers not less than 4
inches on center.
February 2019 5-4

SECTION 6. STEEL STRUCTURES
The provisions of AASHTO LRFD Section 6 shall apply to this section unless
6.1 MATERIALS
Main members (such as girders, rolled beams, lateral bracing, diaphragms,

stiffeners, and vertical connection plates) shall be AASHTO M 270 Grade 36, Grade
50, or Grade 70.
The use of weathering steel is prohibited.
Miscellaneous members (such as armor plates, ladders, catwalks, and clip angles)
shall be AASHTO M 270 Grade 36 or Grade 50.
Anchor bolts shall conform to AASHTO M 314.
6.2 GIRDER DESIGN POLICY
The following policies shall be used for the design of steel girders:
1. Girders shall be designed as a composite section in the region where the

concrete slab is in compression under dead load. For continuous girders, the
regions where the slab is in tension shall be designed as non-composite.
2. Flange plates shall be a minimum of 1 inch thick and 12 inches wide.
3. Use of hybrid sections (flange and web of different materials) in bridge

sections (such as over bents) shall require prior approval of the State Bridge
Engineer.
4. Shop flange splices required by a change in plate thickness or width shall not
be used unless a minimum of 1,500 pounds of structural steel can be saved
by the addition of the shop splice.
5. The minimum radius for heat curving of beams and girders shall be checked
in accordance with AASHTO LRFD Article 6.7.7.2. The plans shall note if
heat curving is prohibited by the specifications.
6. Fabrication, transportation, and erection of structural steel members shall be

considered during design. The length of shipped pieces (girder flanges and
web) joined by bolted field splices shall not exceed 140 feet, and the gross
weight of shipped pieces shall not exceed 50 tons. Longer pieces shall require
the prior approval of the State Bridge Engineer.
February 2019 6-1

7. The following two sets of camber ordinates shall be calculated and shown:
1. Camber due to dead load of steel only.
2. Total non-composite dead load camber (dead load of both steel and
concrete).
Camber ordinates shall be calculated and shown at the same points required
for finished grade elevations, as follows:
• Camber ordinates at tenth points shall be provided on the plans for all
simple and continuous spans.
• Camber ordinates at twentieth points shall be provided for spans greater

than 100 feet in length.
8. Minimum edge distances shall be as follows in the following table:

Bolt Min. Edge
Diameter Distance
In. In.
7/8 1-1/2
1 1-3/4
1-1/8 2
1-1/4 2-1/4
9. The minimum fillet weld size shall be as shown below. Using this table, the
minimum weld size shall be determined by the thicker of the two parts joined.
The minimum fillet weld size shall be used unless a larger size is required by
design based on the calculated stress. The weld size need not exceed the
thickness of the thinner part joined. Fabrication of ancillary members, as
defined in the currently used AWS Bridge Welding Code, is exempted from
these requirements.
Material Thickness of Minimum Size of

Thicker Part Joined Fillet Weld (Inches)
To ¾” inclusive 1/4
Over ¾” to 1½” 5/16
Over 1½” to 2¼” 3/8
Over 2¼” to 6” 1/2
February 2019 6-2

For additional guidance regarding design considerations for fabrication,

transportation, and erection of structural steel members, the designer is encouraged
to refer to AASHTO/NSBA Steel Bridge Collaboration Manual G12.1-2016,
Guidelines for Design for Constructability.
6.3 SHEAR CONNECTORS
Shear connectors shall conform to criteria given in AASHTO LRFD Section 6.10.10.

In addition to LRFD requirements, shear connectors shall only be studs with a
minimum length of 5 inches and shall conform to AASHTO M 169.
6.4 SHOP CONNECTIONS
During fabrication of steel girders, the following policies shall be used for shop
connections:
1. All shop-welded joints shall be made using pre-qualified joints for bridge
applications of the current ANSI/AASHTO/AWS code adopted by ALDOT,
modified in accordance with the provisions of the Standard Specifications and
Special Provisions.
2. Intersecting welds shall not be permitted.
a. Corners of transverse stiffeners shall be clipped and welded as follows:
1) Stiffener-to-web welds shall be terminated 1 inch plus or minus ¼ inch

from the clip.
2) Stiffener-to-flange welds shall be terminated ½ inch plus or minus ¼

inch from the clip and the edges of the stiffener plate.
b. Longitudinal stiffeners shall be cut back a minimum of 2 inches to avoid

intersecting welds.
3. When design lengths of web and flange plates exceed available lengths from
rolling mills, material may be shop spliced utilizing pre-qualified full
penetration butt welds at approximately the one-quarter and/or three-quarter
point of the required material lengths. Shop welded flange splices shall be a
minimum of 2 feet from shop web splices.
February 2019 6-3

6.5 FIELD CONNECTIONS
Bolted connections shall be made using 7/8-inch diameter (minimum) ASTM F3125
Grade A325 High Strength Bolts in standard sized holes. Holes in gusset plates for
lateral bracing member connections may be oversized (hole spacing and edge
distances must be increased also). All bolts, nuts and washers shall be
mechanically galvanized in accordance with ASTM B695 Class 50.
Field welding is prohibited except for attachment of bearings, shear studs, armor
plate splices, pile cap plates and channels and swaybracing.
February 2019 6-4

SECTION 7. ALUMINUM STRUCTURES
The provisions of AASHTO LRFD Section 7 shall apply to this section unless noted
and/or excepted below.
ALDOT has no design considerations beyond those covered in the AASHTO LRFD
Bridge Design Specifications.
February 2019 7-1

February 2019 7-2

SECTION 8. WOOD STRUCTURES
February 2019 8-1

February 2019 8-2

SECTION 9. DECKS AND DECK SYSTEMS
9.1 REINFORCED CONCRETE DECKS
The State Bridge Engineer has furnished a table that addresses the design of the
bridge deck slab. This table is presented in Figure 9-1(page 9-2). Required slab
thickness and reinforcement based on girder type and girder spacing are provided in
the table. Designs shall be prepared based on this information. Any exceptions will
require prior approval of the State Bridge Engineer.
February 2019 9-1

FIGURE 9.1 ALDOT STANDARD BRIDGE DECK – HL93
February 2019 9-2

9.2 INCREMENTAL DECK FINISH GRADE ELEVATIONS
Incremental deck finish grade elevations shall be computed and tabulated in the
plans for all spans except those on zero percent grade and on straight grades (no
vertical curve). This criterion applies to bridges in tangent and in horizontal
curvature. Spans where superelevation transitions fall on the bridge, whether zero
percent or straight grades, shall include incremental deck finish grade elevations.
This data shall be furnished at gutterlines and centerlines of girders from centerline
of bearing to centerline of bearing. For spans 100 feet or less, elevations shall be
furnished at span tenth points between bearings, for spans greater than 100 feet
elevations shall be furnished at span twentieth points.
February 2019 9-3

February 2019 9-4

SECTION 10. FOUNDATIONS
10.1 SUBSTRUCTURE TYPES
For short-span structures (structures with span lengths of 50 feet or less), pile bents
with reinforced concrete caps may be considered if each of the following conditions
is met:
1. Calculated scour does not prohibit the use of this structure type
2. Subsurface material is such that piles can be driven to obtain a minimum of

10 feet of penetration into natural ground
Reinforced concrete framed bents (or hammerhead piers when approved by the
State Bridge Engineer) should generally be used when span lengths exceed 50 feet.
ALDOT discourages the use of hammerhead piers on a single drilled shaft. Any
design utilizing hammerhead piers on a single drilled shaft shall have prior approval
of the State Bridge Engineer.
For designs utilizing drilled shafts, the substructure cap shall be a minimum of 6
inches wider than the column (or the drilled shaft, if the shaft extends to the bottom
of the cap as shown on the contract plans).
Structural seal concrete footings shall be reinforced. Piers in navigable waterways

shall be designed in accordance with Section 3.
10.2 PILE FOOTINGS – SCOUR CONSIDERATIONS
In accordance with FHWA Hydraulic Engineering Circular No. 18 guidelines, the top
of footing for pile footing foundations shall be located below the streambed a depth
equal to the estimated long-term degradation and contraction scour depth. All
exceptions to this requirement shall have prior approval of the State Bridge
Engineer. Influences such as corrosion due to exposed piling, debris collection on
piling, and unbraced pile length (exposed pile below footing plus depth to fixity) shall
be considered in the design of pile footing foundations whenever the top of footing is
to be constructed above the estimated long-term degradation and contraction scour
depth.
February 2019 10-1

10.3 FOUNDATION PILING
Pile section and length shall be determined by the Load and Resistance Factor
Design (LRFD) method, as modified in this and other manual sections,
considering structural capacity, geotechnical capacity, and drivability. The
Maximum Factored Design Load Allowed, PAL, provided in the following tables is
for foundation (footing) piles only. Pile types and sections not shown in the tables
shall use the following equation to determine the load allowed. The loadings will
be less for pile bents depending on the height of the bent and the condition of the
subsurface. Piles without lateral support shall be designed as columns. The
design policy for foundation piles shall use the following equation:
PAL = øALPr , where øAL = 0.65
Factored Structural Resistance of Piles, Pr, is defined by AASHTO. The Alabama

factor, øAL, reduces the resistance to values representative of past Departmental
experience and is used to avoid problems associated with overstressing during
driving.
Uplift in foundation piling is not allowed without prior approval of the State Bridge
Engineer.
Steel “H” Piling (Grade 50 only)
HP10x42 piles shall not be used for designs where “drive to refusal” criteria are
specified for pile installation.
With Pile Points Without Pile Points

Pile Designation
(Øc = 0.5) (Øc = 0.6)
10x42 --- 120 tons
12x53 125 tons 150 tons
14x73 170 tons 205 tons
14x89 210 tons 250 tons
14x102 240 tons 290 tons
14x117 275 tons 335 tons
Table 10-1
Maximum Factored Design Load per Pile for Steel “H” Piling
February 2019 10-2

Precast Prestressed Concrete Piling
Prestressed concrete piling shall be selected from Special Project Drawing No.
PSCP-1.
Maximum Factored
Size of Pile
Design Load Allowed
14-inch Square 155 tons
Table 10-2
Maximum Factored Design Load per Pile for Prestressed Piling
February 2019 10-3

Precast Prestressed Spun Cast Cylinder Piling
Precast Prestressed Spun Cast Cylinder Piling is assumed to have a concrete compressive
strength of 7 ksi and each tendon is made up of 2 - ½ ‘’ diameter, 270 ksi Low Relaxation
strands with an effective stress of 170 ksi.
No. of Maximum Factored

Diameter
Tendons Design Load Allowed
8 650 tons
36'' 12 625 tons
16 600 tons
12 765 tons
42'' 16 745 tons
20 720 tons
16 1020 tons
54'' 20 1000 tons
24 975 tons
24 1255 tons
66'' 28 1230 tons
32 1210 tons
Table 10-3
Maximum Factored Design Load per Pile for Spun Cast Cylinder Piling
10.4 GEOTECHNICAL COORDINATION
Until the Materials & Tests Bureau can develop a sufficient data base upon which to
base their load and resistance factor designs, the following information shall be
provided when requesting foundation design information:
1) Substructure type and location

2) Number of piles/shafts
3) LRFD Service I per pile/shaft (tons)
4) LRFD Strength I per pile/shaft (tons)
5) Elevation at Load ‘P’
6) Pile/shaft size
Extreme Event II will only be reported for stream crossings
February 2019 10-4

SECTION 11. WALLS, ABUTMENTS AND PIERS
11.1 SUBSTRUCTURE
For design criteria, refer to Sections 5 and 10 of this Manual.
11.2 RETAINING WALLS
The Department’s Special and Standard Drawings book has retaining wall details to
address fill heights of up to 34 feet. These details are provided on Standard
Drawing No. RW 10-4. For fill heights greater than 34 feet requiring special design,
the engineer shall be responsible for providing a design that satisfies the latest
AASHTO design requirements. Unless geometrics or foundation conditions dictate
otherwise, information shown on Standard Drawing No. RW 10-4 shall be used as
guidance in preparing the necessary plan details.
Responsibility for design and details of retaining walls shall be as follows:
• Temporary retaining walls – The contractor shall be responsible for providing

the design and details for all temporary retaining walls.
• Permanent conventional walls – The Bridge Bureau shall be responsible for

providing the design and details for all permanent conventional retaining walls
unless a consultant has been contracted to provide such items as part of a
complete set of plans.
• Permanent proprietary walls – The contractor shall be responsible for

providing the design and details for all permanent proprietary retaining walls.
February 2019 11-1

February 2019 11-2

SECTION 12: BURIED STRUCTURES AND TUNNEL LINERS
12.1 REINFORCED CONCRETE BOX CULVERTS
The Hydraulic Section of the Bridge Bureau is responsible for sizing all bridge
culverts. The Hydraulic Section is responsible for recommending whether the
culvert shall be cast-in-place or precast, and the culvert type shall be shown on the
roadway plans. The Bridge Bureau (or a selected consultant) is responsible for the
design and details of cast-in-place culverts and for reviewing the contractor's
structural details for precast culverts. The State Bridge Engineer will furnish culvert
details (standards) as needed.
• Cast-In-Place Culverts
The Bridge Bureau (or a selected consultant) is responsible for the design
and details of all cast-in-place concrete box culverts, open bottom culverts
that are to be constructed on sound rock foundation, and special culvert or
special hydraulic structures. The Roadway Designer is responsible for
providing the basic geometric, fill height, and slope information needed for the
design and detailing of the hydraulic structure.
• Precast Culverts
The structural design and details for precast culverts shall conform to the
provisions of ASTM C 1577 (using LRFD design methodology). For culvert
openings and fill heights not covered in this specification, the contractor shall
submit a design (prepared and stamped by an Alabama Registered
Professional Engineer not employed by the Alabama Department of
Transportation) to the State Bridge Engineer for approval in accordance with
the Standard Specifications. The Bridge Bureau is responsible for the review
of the details and designs submitted.
February 2019 12-1

February 2019 12-2

SECTION 13: RAILINGS
13.1 BRIDGE RAILINGS
Use bridge railing as detailed on Bridge Special Project Drawing BBR-1, BBR-2 or
BBR-M as appropriate. Use approach railing and/or barrier as per roadway
standard drawings and/or plans.
Bridges on secondary roads and other non-interstate roadways, Federal

highways, or State roads may continue to use the TL-3 Jersey rail.
February 2019 13-1

February 2019 13-2

SECTION 14: JOINTS AND BEARINGS
The requirements of AASHTO LRFD Section 14 shall apply to this section unless
14.1 EXPANSION JOINTS
Generally, use armor plate open joints as shown on Bridge Special Project Drawing
SBD-1. For bridges with high skews or other unusual joint situations for which the
guidelines below might not apply, an alternate arrangement may be proposed to the
Bridge Engineer for approval.
Typically, joints shall be set for a 1½’’ opening (perpendicular to joint) at 70°F unless
otherwise required and subsequently indicated on the plans. The calculated
minimum joint opening should be no less than ½’’. When the calculated maximum
joint opening exceeds 3’’, a structural steel expansion dam shall be used.
Example drawings of current expansion dam (finger joint) details are shown in the
Quality Control Manual for Bridge Plan Detailing or are available by contacting the
State Bridge Engineer. Finger tooth joints shall be constructed with a continuous
neoprene trough (minimum 3/16 inches thick) for the full length of the joint.
14.2 BEARING DEVICES
Bearings shall preferably be elastomeric Type 2, Type 4, or Type 5, in accordance

with the Standard Specifications. Type 1 bearings are approved for use only on
short span precast structures.
Elastomeric bearings shall be designed using “Method A,” as described in the

currently adopted edition of AASHTO LRFD Article 14.7.6, with a durometer
hardness of 50 for laminated pads and a durometer hardness of 60 for plain pads.
The minimum distance from the edge of the elastomer (or the corner of the
elastomer when bearings are skewed relative to the cap) to the edge of the cap or
pedestal shall be 4 inches.
14.3 ANCHOR BOLTS
Anchor bolts shall be set in corrugated anchor bolt wells. See Bridge Special Project
Drawing SBD-1 and the Quality Control Manual for Bridge Plan Detailing for
pedestal, anchor bolt and anchor bolt well details. For anchor bolts with diameters
larger than those specified on Special Project Drawing SBD-1, the anchor bolt well
diameter should be increased proportionally. A minimum of 5 ½’’ should be provided
between the edge of the cap or pedestal and the centerline of the anchor bolt.
February 2019 14-1

February 2019 14-2

SECTION 15: DESIGN OF SOUND BARRIERS
February 2019 15-1

February 2019 15-2

SECTION 16: BRIDGE RATING

Bridges designed in-house with LRFD shall be analytically load rated in accordance
with the requirements of the current AASHTO Manual For Bridge Evaluation and the
FHWA October 30, 2006, policy memorandum on Bridge Load Ratings for the
National Bridge Inventory (available at
http://www.fhwa.dot.gov/bridge/nbis/103006.cfm) using the current Posting Trucks
as shown in Figure 16.1. Rating models for pre-stressed girder bridges, steel girder
bridges, and steel reinforced concrete bridges will be built on the most current
version of the AASHTO Bridgeware bridge rating program. When a bridge rating
model is completed, the Maintenance Bureau shall be notified with the results in
writing.
Bridges designed by consultants shall be rated by the consultant, using the same
parameters as noted above. If the consultant does not have the AASHTO
Bridgeware bridge rating program, then the rating program used shall be able to
produce a bridge model that can be imported into the Department’s version of
Bridgeware. The consultant shall provide the Bridge Bureau with the rating results in
electronic format and a compatible bridge model when or before the final contract
drawings are delivered.
February 2019 16-1

Figure 16.1
ALDOT Posting Vehicles
February 2019 16-2

SECTION 17: STRUCTURES FOR TRAFFIC CONTROL DEVICES AND

HIGHWAY LIGHTING
All structures shall be designed in accordance with the requirements of the ALDOT
Standard Specifications section 718.03(a)2 unless noted and/or excepted below.
17.1 OVERHEAD HIGHWAY SIGN STRUCTURES
Overhead highway sign structures shall be designed in accordance with the

AASHTO Standard Specifications for Structural Supports for Highway Signs,
Luminaires, and Traffic Signals, 6th Edition, with 2015 and 2019 Interim Revisions.
• Overhead Sign Bridge (OHSB) and Overhead Cantilever (OHC):
The contractor is responsible for submitting completed design(s) of required

overhead sign structures as well as the accompanying foundation(s) with
details, including shop drawings, in accordance with Standard Specification
Section 715, Overhead Roadway Sign Structures, and Standard Specification
Section 718, Structures for Traffic Control Devices and Highway Lighting.
• Bridge Mounted and OHSB or OHC Mounted to Bridge Substructure:
Definitions:
• Sign Structure – The structure that is attached to a bridge member

providing support to the sign brackets.
• Sign Brackets – The structural members to which the sign is directly

attached.
The Bridge Bureau or consultants under direct contract with the Department
shall be responsible for providing the design and details for bridge-mounted
signs or sign structures mounted to a bridge substructure. The contractor is
responsible for submitting shop drawings in accordance with Standard
Specification Section 715, Overhead Roadway Sign Structures and Standard
Specification Section 718, Structures for Traffic Control Devices and Highway
Lighting.
• Re-evaluation of Existing OHSB or OHC:
The Bridge Bureau or a consultant under direct contract with the Department
shall be responsible for re-evaluating existing OHSB or OHC sign structures
where additional signage is needed or existing signs are replaced with larger
ones. The Specification and design methodology used to design the structure
shall be the specification and design methodology used to conduct the
analysis.
February 2019 17-1

February 2019 17-2

SECTION 18: PRE-CAST BRIDGES
The context of Pre-Cast Bridges used here refers to bridges consisting of pre-cast
concrete bridge components and are normally used for bridges located on off-
system roadways. These include pre-cast superstructure channel beams, pre-cast
barrier rail, pre-cast abutment caps, pre-cast intermediate bent caps, abutment and
wing panels.
The Bridge Bureau maintains an inventory of Bridge Special Project Drawings that
contain standard details (includes spans, barrier rail, abutments and bents) for span
lengths of 24, 34 and 40 feet and for bridge widths (gutter to gutter) of 24.5, 28 and
40 feet.
February 2019 18-1

February 2019 18-2

APPENDIX A: PROCEDURE FOR PROPOSING CHANGES TO THE

DESIGN MANUAL
To effect a change to the document:

1) copy & paste the passage in question into an e-mail twice
2) on the second paste, make the proposed change, with all changes in color
(deletions in red, additions in blue)
3) send the e-mail to the Miscellaneous Structures and Bridge Design Section
Supervisor for distribution to the Design Manual Oversight Committee and
resolution.
February 2019 A-1

February 2019 A-2

APPENDIX B: RECORD OF REVISIONS
Modifications reflected in this version (month year) of the Design Manual include:
1. Entire Manual
Re-write and update for AASHTO LRFD 8th Edition - February 2019
February 2019 B-1

February 2019 B-2

END OF DOCUMENT
February 2019

Structural Design Manual: ALDOT Bridge Bureau

Uploaded by

Copyright:

Available Formats

Structural Design Manual: ALDOT Bridge Bureau

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Structural Design Manual: ALDOT Bridge Bureau

Uploaded by

Copyright:

Available Formats

What is the purpose and scope of this manual?

What is the purpose and scope of this manual?

What design method/specifications are used?

What design method/specifications are used?

Structural Design

ALDOT Bridge Bureau

I. ALDOT Policy Statement ---------------------------------------------------- v

SECTION 1. INTRODUCTION -------------------------------------------------------- 1-1

SECTION 2. GENERAL DESIGN AND LOCATION FEATURES ------------2-1

2.1 Deformations ----------------------------------------------------------------- 2-1

SECTION 3. LOADS AND LOAD FACTORS ------------------------------------- 3-1

3.1 Permanent Loads ----------------------------------------------------------- 3-1

SECTION 4. STRUCTURAL ANALYSIS AND EVALUATION --------------- 4-1

SECTION 5. CONCRETE STRUCTURES ----------------------------------------- 5-1

5.1 Concrete Compressive Strengths --------------------------------------- 5-1

SECTION 6. STEEL STRUCTURES ------------------------------------------------ 6-1

6.1 Materials ----------------------------------------------------------------------- 6-1

SECTION 7. ALUMINUM STRUCTURES ------------------------------------------ 7-1

SECTION 8. WOOD STRUCTURES ------------------------------------------------ 8-1

SECTION 9. DECKS AND DECK SYSTEMS ------------------------------------- 9-1

9.1 Reinforced Concrete Decks ---------------------------------------------- 9-1

SECTION 10. FOUNDATIONS -------------------------------------------------------- 10-1

10.1 Substructure Types ------------------------------------------------------- 10-1

SECTION 11. WALLS, ABUTMENTS AND PIERS ----------------------------- 11-1

11.1 Abutments, Bents, Piers ------------------------------------------------- 11-1

SECTION 12. BURIED STRUCTURES AND TUNNEL LINERS ------------- 12-1

12.1 Reinforced Concrete Box Culverts ------------------------------------ 12-1

SECTION 13. RAILINGS --------------------------------------------------------------- 13-1

13.1 Bridge Railings ------------------------------------------------------------- 13-1

SECTION 14. JOINTS AND BEARINGS ------------------------------------------- 14-1

14.1 Expansion Joints -----------------------------------------------------------14-1

SECTION 15. DESIGN OF SOUND BARRIERS --------------------------------- 15-1

SECTION 16. BRIDGE RATING ------------------------------------------------------ 16-1

SECTION 17. STRUCTURES FOR TRAFFIC CONTROL DEVICES

SECTION 18. PRECAST BRIDGES ------------------------------------------------- 18-1

APPENDIX A. PROCEDURE FOR PROPOSING REVISIONS TO THE

APPENDIX B. RECORD OF REVISIONS ------------------------------------------ B-1

February 2019 iii

THIS PAGE INTENTIONALLY LEFT BLANK

I. ALDOT POLICY STATEMENT

All bridge and miscellaneous transportation structures in Alabama shall be

II. PURPOSE AND SCOPE

This manual contains specific design criteria policies mandated by the

• To provide interpretation and consistency in the application of the

• To encourage the uniform preparation of plans and specifications.

• To provide direction to be followed on projects under the authority or

Exceptions, based on sound engineering principles and judgment, are

ALDOT exception to AASHTO:

A description of the ALDOT exception is given here.

This manual will be continually updated as revisions and improvements are

William T. Colquett, P.E.

III. DESIGN METHOD/SPECIFICATIONS

All bridge and miscellaneous transportation structures in Alabama shall be

IV. RELATED ALDOT MANUALS/DOCUMENTS

Other documents maintained and/or used by the ALDOT Bridge Bureau

• Bridge Plan Development QC/QA Plan and Checklist

• ALDOT Guide for Developing Construction Plans

• Bridge Special Project Drawings

• ALDOT Standard Specifications for Highway Construction