Design

g of Bridge
g
Main Girders
According to ECP

Assis. Prof. Dr. Ehab B. Matar

Design Phases of Main Girders
1. Structural analysis for the main system determining the max.
and min. straining actions at critical sections
2. g of Web Plate
Design
3. Design of Flange Plate
4. Design of Stiffeners (end bearing and intermediate)
5
5. Design of Connections between web plate and flange plate
6. Design of Splices
7. Check fatigue for all details
Bridges Main systems
1- Structural Analysis

 Structural analysis is carried out using either influence lines,

grillage analysis or finite elements depending on complexity of
structures and its importance.
 Max. and Minimum shear, moments, reactions…. are determined
at critical sections
sections.

Stress range

Stress range
Stress range
2- Design of Web Plate
 This includes the following tasks:
1. Determining Web height
2
2. Determining Web thickness
3. Checking shear Buckling
 2.1 Web height
 Overall depth, h:
 Lo/18 ≤ h ≤ Lo/12 (highway two lanes)
 L /10 ≤ h ≤ L
Lo/10 Lo/7
/7 (railway
( il single
i l ttrack)
k)
 For double tracks railway or four lanes roadway, increase
the above limits by 60
60-85%
85%
 If the maximum moment is known; the web height can be
approximately calculated as
3Mk M
h or d  3  5.3  5.7 3
2 Fb Fb
 d= plate girder depth (cm)
 M= maximum bending moment (t.cm)
 k= eb plate  100
k ratio of height to thickness of web
 Fb= allowable bending stress ≈ 0.58 Fy
2.2 Web Thickness

 web thickness, tw:

 tw ≥8mm

d 830
* In any case 
tw Fy
d 190
* when transverse stiffeners are used 
tw Fy
d 320
* When longitudinal (at d/5) and transverse stiff. used 
tw Fy
2 3 Shear Buckling
2.3
 No need to check shear buckling resistance if :
 for un-stiffened web d w / t w  105 / Fy
 for stiffened web d w / t w  45 /
kq
Fy

where K q  buckling factor for shear

 4  (5.34 /  2 ) for
f   1.0
10
 5.34  (4/ 2 ) for   1.0
where   d1/d

d1
Shear Buckling Resistance
 If the above mentioned limits are exceeded the shear buckling
resistance should be checked as follows:

d
tw Fy
* Calculate q 
57 Kq
* For q  0.8 then q b  0.35Fy
* For 0.8  q  1.2 then q b  (1.5 - 0.625q )0.35Fy
0.9
* For q  1.2 then q b  * 0.35Fy
q
 It should be noted that longitudinal stiffener at mid depth would be
more effective
ff ti forf sections
ti subjected
bj t d tto pure shear
h th th
than thatt
positioned at d/5 for pure bending.
 For continuous plate girder, the web panel over an interior
support will be subjected to simultaneous action of bending
moment and shearing force. Therefore:
 If the actual shear stress qact ≤0.6qb then the allowable bending
stresses in the girder flanges will not be reduced and should
not exceed 0.58Fy.
 If the actual shear stress qact >0.6qb then two alternatives may
be followed. The first is to reduce the allowable bending g
stress for flange plates according to the following interaction
equation.
  qact 
Fb  0.8  0.36  Fy
  qb 
 The second alternative is to design
g the girder
g flanges
g to
resist the whole acting bending moment without any
participation of web for resisting bending moment without
reducing the allowable bending stress.
 Example
Design a continuous two spans welded plate girder as shown below for a
roadway bridge. The cross girders are arranged each 2.4m. The deck slab is 20cm
thick and the asphalt cover is 10cm. The steel used for the design of all elements is
St. 37. Moreover, design a field splice located at 16.8m from the end support. The
bending moments and shearing forces at the critical locations are tabulated as
follows:
Sec. Md.l (t.m) Qd.l (t) Mll+I (t.m) Qll+I (t)
1 0 +38.2 0 +50.8
2 +171 0 +267 +4 43
+4.43
3 -305.3 -63.6 -296 -61.65
4 +96 -33.07 +96.69,-98.63 -34.92,+3.36
Solution
 Proportioning of plate girder
3Mk 3 3 * (296  305.3) *100*100
 d 3   186cm  190cm where k is
2Fb 2 *1.4
assumed 100
 Design of web plate
190 190
 d / tw   tw   1.56cm
Fy 122
 By using vertical stiffeners arranged @2.4m (distance between
cross girders), then,
d1 240
    1.26
d 190
 kq  5.34  (4 /  2 )  5.34  4 /(1.26) 2  7.85
k 7.85
 d t  45 q  45  81.37
w Fy 2.4
190
 t w   2.34cm whichis a largethcikness
81.37
 Assume tw = 16mm and check shear buckling resistance.
d tw Fy 190 1.6 2.4
 q    1.150.8  q  1.2
57 kq 57 7.85
 qb  (1.5  0.625q )(0.35Fy )  (1.5  0.625x1.15)(0.35x2.4)

 qb  0.66t / cm2
Q 125.25
 q    0.41t / cm2  qb  safe
Aw 190x1.6
3- Design of Flange Plate
 This includes the following tasks:
1. Determining Flange cross section (using Flange Area
Method)
2. Determining Flange width and thickness
3. Checking Bending Stresses
3.1 Flange Area Method
MY
  Plate Girder
I
2 3
 d  twd
I  2 Af    b

2 12

tf
c
d 2 twd 3 d 2  Aw 
I  Af    Af  

d
2 12 2  6 
 A 
I / Y  d  Af  w 
Welded Plate Girder

 6 
M
  Fb 
 A 
d  Af  w 
 6 
 M A
 Af   w
Fb d 6
For bolted or riveted BUS assume bolts arranged @4
M A 3 M A
 Af   w*   w
Fb d 6 4 Fb d 8
where A f  b * t f ; b  2C  20  30%d

3.2 Local Buckling limits

C C D b
tf tf
Section class Part Stress Profile dw dw
t

tw tw h

Rolled section Welded section t

Compact
p Flange
g Uniform Comp.
p C / t f  16.9 / Fy Rolled Sec.
section
C / t f  15.3 / Fy B.U.S
Non-compact Flange Uniform Comp. C / t f  23 / Fy Rolled Sec.
section
C / t f  21 / Fy B.U.S
Remember
 Whenever the width / thickness ratio of compression
flange exceeds the aforementioned limits, the flange should
be treated as a slender section and the effective flange
area should be calculated to account for local buckling.
 The thickness of flange plates as well as web
plates should be reduced by 1.0mm in design calculations
due to the effect of undercut in welding unless special
precautions
ti in
i the
th welding
ldi ttechnique
h i are ttaken.
k
Note that:
 When plates with  Change of flange plate
width or thick.
unequal
q thickness or
width butt welded
g
together, the thicker or
wider plate should be 4
4

2−4mm
1 1
tapered with a slope
not exceeding one to 2mm

four as shown

0cm
R=6
 3.3 Allowable Compressive Stresses
The allowable compressive
stresses in the compression
flange depend on whether the
flange is braced laterally or un-
braced. The lateral unsupported
length of the compression flange
Lu is calculated as follows:
For deck railway bridges with
open timber floor where there
exist upper wind bracing or not,
and with the existence of cross
girders that are rigidly connected
to the main girder compression
flange, then, Lu = distance
between x-girders.
For deck railway bridges with
ballasted floor or for roadway
bridges where the compression
flange is supported by
continuous reinforced concrete
or steel deck, where the frictional
or connection of the deck to the
flange is capable to resist a
lateral force of 2% of the flange
force at maximum bending
moment, then, Lu = 0.
For continuous
deck roadway
dec oad ay oor
railway bridges
where the
compression flange
at interior supports
is located in the
bottom side of the
girder away
g y from the
deck slab, then,
Lu = the distance
between the centers
off iintersection
t ti off the
th
lower wind bracing
with the
compression flange
Lu = if there is no
lower wind bracing
or transverse bracing g
then Lu is taken as
the distance from the
point of maximum
bending moment to
the point of contra-
flexure.
 •Lateral
aea u unsupported
suppo ed length
e g for
o through
oug bbridge
dge ((+M
region)
 The lateral unsupported length of the Lu  2.5 * 4 EI y a
compression flange is taken as the full
3 2
girder length if the compression flange is d d B
unrestrained against lateral bending. If  1  2
3EI1 2 EI 2
the cross girders and the stiffeners
forming U-frames, then,
 Wh
Where
 E= The Young's modulus of steel (t/cm2)
 Iy= moment of inertia of the chord

d1
d2
member about the Y-Y axis (cm4) as
I1
shown
 a = distance between the U- frames
(distance between x- girders) I2
  = the flexibility of the U- frame
 d1 = distance
di t ffrom th
the centroid
t id off th
the
compression flange to the nearest face of B
the cross girder of the U-frame.
 d2 = distance from the centroid of the
compression flange to the centroidal axis
of the cross girder
 I1 = Moment of inertia of the vertical
member forming the arm of the U-frame
about the axis of bending.
 I2 = Moment of inertia of the cross girder
 B = distance between centers of
consecutive main girders connected by
U-frame.
 1.0m 7.5m 1.0m

1.25 2.5m 2.5m 1.25

Continue Example 1 2 4
Bridge Cross section

16.8

24m 24m

 Flange area Method  Assuming the compression flange is braced laterally by the lower
wind bracing which has joints @240cm (distance between cross girders),
 For sec. 3, moment and shear acting together, therefore, checking then Lu=240cm.
q 0.41  Checking whether lateral torsional buckling controls the
  0.62  60% , then, a reduction in the allowable bending stress
qb 0.66 allowable compression stresses or not as follows:
20 b f
should be carried out as follows  
20 x 60
 774 . 6 cm  L u
Fb  0.8  0.36q / qb Fy Fy 2 .4
 2

Fb  0.8  0.360.41/ 0.662.4  1.38t / cm2

1380 A f 1380 x 3 x 60  323 . 78   323 . 78 
.C b  x (1 . 75  1 . 05 x    0 . 3 
d .F y 196 x 2 . 4  601 . 3   601 . 3 
 Calculating the flange area at sec.3 as follows: 
1380 A f
M Aw 601.3E 2 190x1.6  .C b  580 . 86 cm  L u
 Af      178.66cm2 d .F y
Fb d 6 1.38x190 6  Therefore Fbc =1.38t/cm2& Ft=1.4 t/cm2
 Assuming bf=0.3d=0.3x190=57cm→60cm  F  
601 . 3 E 2
  1 . 38 t / cm 2 O.K safe in both tension and
43 ,543
 Then tf=178.66/60=2.98cm→3cm
compression.
c 300  16 / 2 21
   9.73   Checking fatigue stress by considering only 60% of the live loads
tf 30 Fy are acting i.e. 0.6x274.32=164.6tm.
164 . 6 E 2
 However, although the flange satisfied the limit of compact  Stress range =  0 . 378 t / cm 2
43 ,543
section ( 15.3 / Fy ) but the web is non-compact, therefore, the whole section  For ADTT >2500 truck, No. of stress cycles =2E6 and for welded
plate girder Class B' is taken therefore the allowable fatigue stress range
will be considered non-compact.
Fsr=0.85t/cm2. Therefore, the section is safe.
 Calculating the flange area at sec.2 as follows:  Checking Actual stresses at section 2
M Aw 438E 2 190x1.6 190 3 x1 . 6  2 x  50 x 2 . 4 3 2 
 Af      114cm2 I gross    50 x 2 . 4 x 95  1 . 2  
Fb d 6 1.4x190 6  12  12 
 Assuming bf=50cm  I gross  3,135 , 714 cm 4 , Z  32 ,194 cm 3

 Then tf=114/50=2.28cm→2.4cm  Assuming the compression flange is braced laterally by the

c 250  16 / 2 21 existence of R.C. deck directly rested over compression flange therefore,
   10.08  Lu=0. Therefore, there is no need to check Fltb.
tf 24 Fy  Therefore Fbc 4 t/cm2& Ft=1 4 t/cm2
b =1 1.4 1.4
438 E 2
 Checking Actual stresses at section 3  F 
32 ,194
  1 . 36 t / cm 2 O.K safe in both tension and

I gross 
190
3
x1.6  60x3
 2x
3
2
 60x3x95  1.5  compression.
12  12   Checking fatigue stress by considering only 60% of the live loads
is acting. The live load is ranged at this section between +250.5 tm and -
 I gross  4,267,213cm4 , Z  43,543cm3 73.971 tm. Then,
 Example for through bridge
 A railwayy through
g p plate g
girder
bridge of 27 m simple span has
two main girders 9 m apart. The
bridge is for double track and has
an open timber floor. The cross
girders are arranged every 2.25 m.
 The bridge is provided by stringer
bracing, while braking force
bracing is not arranged. The
material off construction is steel 44;
the weight of the timber floor for
each track is 0.6 t/m’.
 Calculate Lu considering, for main
girder tw=20mm, dw=3000mm,
Mmax=1060mt,
=1060mt Qmax=160t,
=160t while
for XG Pl#1000x20/2Pl#300*40mm
 Solution
 For the main girder, tw=20mm,
dw=3000mm
 Af=M/(dF
M/(dFb))-A
Aw/6
 Af=1060*100/(300*1.6)-
2*300/6=120.8cm2
 Bf=0.2*300=60cm

d1
d2
 tf>120.8/60>2.01cm I1

 c/tf<21/sqrt(Fy)tf=2.4cm
=2 4cm I2

 Z=(50x2x27.4+60x2.4x1.2)/(60x2.4+50
x2)=11.94cm B

 Iy=2.4x60^3/12+50X2^3/12=43233cm4
 I2=2X100^3/12+2x(30x4^3/12+30x4x5
2^2)=815947cm
2 2)=815947cm4
 d1= (302.4-100-11.94)=190.46cm
 d2= 190.46+100/2+4)=244.46cm
 B=930cm
 Upon calculating the
I1, the section is
composed of part of
the web plate (25
twxtw), vertical stiffener
assumed 250x20 mm
(satisfying local
buckling) and the
b k t is
bracket i tto be
b
defined according to
max. distance allowed
by train edges.
 Calculate the centriod
 X=(25x2x1+40x2x22+
50x2x43+25x2x56.5)/(
2x(25+40+50+25)=31.
9cm d
3
d B
2
 1  2
 I1=25x2x30.9^2+40^3x 3EI1 2 EI 2
2/12+40x2*9.91^2+50
x2x11^2+2x25^3/12+2 
190.46^3

244.46^ 2 * 930
 2.6e  2cm
3 * 2100 *111226 2 * 2100 * 815947
x25x24.6^2=111226c
Lu  2.54 EI y a  2.5 * 4 2100 * 43233 * 225 * 2.6e  2  379cm  a  2.25m  ok
m4
3- Design of Stiffeners

 This includes the following tasks:

1. Design
D i off vertical
ti l stiffeners
tiff (Whether
(Wh th end
d bearing
b i or
longitudinal stiffeners)
2. Design
g of horizontal stiffeners
Importance of stiffeners
 Reducing slenderness ratio of web plate
 Increase the shear capacity
p y of web p
plate

Location of stiffeners
 Vertical stiffeners are located at location of X-
girders and at supports
 Horizontal stiffeners at a distance of d/5 from
compression flange and at d/2
A- Vertical Stiffeners
Compression Flange

Tension Flange x

The outstanding length of vertical stiffeners

1- stiffeners in pairs x  dw/30 + 5 cm
2- single stiffeners x dw/30 + 10 cm
 Vertical intermediate stiffeners composed of single or
pair
i off symmetrical
t i l sections
ti while
hil End
E dbbearing
i stiffeners
tiff
should be in pairs fastened on each side of the web
 End bearing stiffeners should be well ground or
machined to fit tightly against the top and bottom flange
angles and should never be crimped.
 Vertical stiffeners act as a compression members with
buckling length equal to 0.8dw
 For the sake of design of the vertical stiffeners it will be
considered as a column of cross section consisting of
the area of angles and a certain length of the web ( 25
tw for intermediate vertical stiffeners and 12 tw for end
bearing stiffeners).
stiffeners)

25tw 6tw 6tw

Intermediate End Bearing

Stiffener Stiffener
• End Bearing Stiffeners

 Design Steps:
 1- Define the design force d.F (Max. Reaction at support)
 2- Choosing stiffeners in pairs x  dw/30 + 5 cm
 3- Required area of End bearing stiffeners
 Areq = d.F/1 t/ 2  Astiff + 12tw2
d F/1 t/cm
 Astiff = (Areq - 12tw2)
 4- Choose stiff. sections to avoid local buckling such that x 21

t stiff fy
 5- Calculate the slenderness ratio of the proposed column as follows
 calculate moment of inertia and cross sectional area Ix & A &
 Ix lb 0.8hw
i  
 A i i
6- Calculate the permissible buckling stress Fpb
 7- d F / A  Fpb
7 Check that Fact = d.F
 8- Design the weld between the stiffeners and the web plate such that the weld
in upper and lower thirds can resist the whole design force
•Intermediate Vertical Stiffeners

 Design Steps:  0.35Fy 

 1 Define the design force d
1- F = Qd  0.65
d.F  1Qact
  qb 
 2- Choosing single stiffeners x  dw/30 + 10 cm
 3- Required
q area of Intermediate vertical stiffeners
 Areq = d.F/1 t/cm2  Astiff + 25tw2
 Astiff = (Areq - 25tw2) x 21
 4- Choose stiff. sections to avoid local buckling such that 
t stiff fy
 5- Calculate the slenderness ratio of the proposed column as follows
 calculate moment of inertia and cross sectional area Ix & A &
 lb 0.8hw
i
IIx  
 A i i
6- Calculate the permissible buckling stress Fppb
 7- Check that Fact = d.F / A  Fpb
 8- Design the weld between the stiffeners and the web plate such that the
weld in upper and lower thirds can resist the whole design force
•Horizontal Stiffeners

 The Egyptian code of practice requires that the

hori ontal stiffeners satisfies the follo
horizontal following
ing
stiffness:
 F hl.
For hl Stiff
Stiff. At d/5,
d/5 momentt off inertia
i ti >4d(tw)3
 For hl. Stiff. At d/2, moment of inertia>d(tw)3
 Local buckling should be checked to satisfy the
relation of x 21

t stiff fy
4-Curtailment of Flange Plates
 Why curtailment is needed?
 Bending moment varies along bridge span, therefore it may be
economic
i tto change
h th
the plate
l t girder
i d section
ti tto gett maximum
i
utilization of steel strength.
 Ho co
How could
ld we
e specif
specify the ccurtailment
rtailment location?
 based on developed formulas by Johnson et al [1] to find the
minimum volume of steel that will yyield minimum steel weight
g
 1. For Parabolic variation of bending moment
for simple or continuous girder

M A A f1 A f2
Af 1   w
d .Fb 6
M max Aw
Af 2  
d .Fb 6 x
L

Vol.  A f 2 L  x   A f 1.x M Mmax

M  L3  L2 x  2 Lx 2  x 3  Aw .L
Vol.  max  2
 
d .Fb  L  6

 (vol.) 4 L2 L
 0  x  Lx   x 
2

x 3 3 3
and
A f1 5

A f2 9
2. For Parabolic variation of bending
g
moment for cantilever girder

M max  L2  L2 x  x 3  Aw L
vol   2
 
d .Fb  L  6
 (vol ) L
 0  3x  L  x 
2 2

x 3
Af 1 1

Af 2 3
5- Connection between Flange
and web plates
 Connection is either by using bolts or welds
1.5mm
m
 Procedure
 ECP recommends continuous fillet weld between flange
and web plates in case of dynamic loading
 The size of welding is given by
Q
QY
q  f weld .2 s
I
 Where
 Q = maximum shearing g force at support
pp
 Y = first moment of area of flange plate about centroidal axis of the
section
 I = Moment
M t off inertia
i ti off plate
l t girder
id
 s = size of welding
 fweldld = allowable stresses in fillet weld = 0.2Fu
0 2Fu
 Fu = ultimate strength of the base metal.
 Minimum sizes of weld

tmax S mm
mm
10 4
10-20 5
20 30
20-30 6
30-50 8
50-100 10

Fatigue strength of the fillet weld under the effect of shear flow due to
live load plus impact should be checked, the connection is detailed as
class D (Group 3 Fasteners)
 Example
 Given: Qt=125
125.25t&
25t& Ql.l
Ql l=57
57.15t
15t , II=44,267,213cm4
267 213cm4 &
M.G.2Pl#600X30/1900X16mm, St. 37
 Design of the connection between the flange plate and the web plate.
 Maximum shear flow is at sec. sec 3 where Q
Q=125
125.25t.
25t
 Y=first moment of area of flange plate about N.A.
 Y  60 x3 x(1.5  95)  17,370cm 3
Q.Y 125.25 x17,370
 q   0.51t / cm
I 4,267,213
 Assuming direct contact between the web plate and the flange
q  2 Sx0.2 Fu x1cm
therefore, 0.51 based on the maximum thickness of
S  0.35cm  6mm
2 x 0 .2 x 3 .6
flange plate = 30mm.
 Checking the fatigue resistance where 60% of live load is only
considered i.e. 0.6x57.15=34.29t.
34.29 x17,370
 The shear flow due to this live load qll  I  0.14t / cm
4,267,213
 The allowable stress range based on No. of stress cycles of 2E6
and Detail D Groupp 3, is 0.71t/cm2.
 2 SxFsr  qll  I

 2 Sx 0.71  0.14  S  0.1cm O.k safe
6- Splices
 why
yap
plate girder
g may
y be spliced?
p
 Un-sufficient plates lengths (Web plates ≈ 6m long,
Flange plates ≈12-18m).
 Th designer
The d i may ddesire
i to use spliced
li d jjoints
i to aid
id
in cambering.
 Change the girder cross section to fit the actual
bending moment.
 Transportation
p of full length
g p plate g
girders pplays
y an
important role in locating spliced joints. Highway
road system conditions, maximum limit of legal
loads over existed bridges and maximum crane
capacities limits the maximum length and weight of
plate girders to be transmitted in one time.
Shop Splicing
 Generally, flange and web plates are spliced using single or
double V-joints.
 J and U joints require the least amount of weld of metal but
require the plates to be prepared by planning or milling which is
impractical in most structural fabricating shops.
 This limits the preparation to flame beveling giving a VV-joint.
joint
Single V-joint may be acceptable if the plate thickness is up to
25mm.
 For thicker plates double V-joints are preferred since they require
less weld metal.
 It should be remembered that a singleg V-joint
j will p
produce more
angular distortion which is increased rapidly as the flange
thickness increases.
Design forces
 Splices in webs of plate girders must be
designed to resist the moments and shearing
forces at that section. The principle stresses
in welds are determined from:
 The greatest bending moment at the splice
andd th
the corresponding
di shearing
h i fforce.
 The greatest shearing force at the splice and
the corresponding bending moment.
 f q

Fig. (17) Staggering compression and tension flanges butt weld

The stresses in butt welds:
Q
q  0.35 Fy for Good weld
 For
F ththe webb Aw
 0.385Fy for Excellent weld
My
f   0.7 F pt i.e.  0.7x0.58Fy  0.4Fy for Good weld
 For the flange I
 0.58Fy for Excellent weld
Field Splicing
 Arrangement: Generally each girder of a bridge is
assembled of two or three parts at the bridge
location cite
cite.
 Methods: The girder assembly is carried out either
by welding or by bolting.
 Design forces: The ECP [2] cl. 7.5 recommends
that, splices should be designed on the maximum
bending resistance of the girder section and the
actual shearing force at the splice location.
 Execution: Generallyy welded field splices
p requires
q
testing either by ultrasonic, X-ray or any other
testing technique which increases the cost.
 Welded field splices
the German window splices as shown in Fig. (18) Which is assembled as
follows:
(2)
(1) (1)

(4)

(3) (3)

(1) (1)

(2)
German Window
Fig. (18) The German window for field splice
 A short portion of web is omitted and the adjacent parts of the web are
shop welded to the flanges (see ends of weld 1).
 The flanges welded first where they are not restrained by the web.
Moreover, the roots of these welds are fully accessible.
 The
Th window
i d i.e.
i theth missing
i i piece
i off the
th webb is
i then
th inserted.
i t d It is
i
slightly curved so that no shrinkage stresses will arise when the piece is
welded to the remainder of the web.
 The remainder welds between the web and the flanges are deposited
last.
 Bolted field splice

Q Q Q Q

S2 S2 S2 S2

m m m m m m

Detail of Field Splice in bolted Main Girder Detail of Field Splice

Flange
g Pl. Spl.
p : Direct Method
Flange < Spl. : Two Cuts in welded plate girder
 Q Q tsp2

S2 S2

m m m m m m

Detail of Field Splice in bolted Main Girder

Flange Pl
Pl. Spl
Spl. : Direct Method
Flange < Spl. : Two Cuts
Remember
Ignorance with Code
leads to
Thank you