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New York State Thruway Authority

Thruway Structures Design Manual - 4th Edition

Image of manual coverTo order a hard copy of the Thruway Structures Design Manual send a check for $75.00 to:

New York State Thruway Authority
Attention: Contracts Unit
200 Southern Blvd
Albany, NY 12209

Outside Cover PDF  | Inside Cover PDF | Endorsement Letter PDF 

Table of Contents

Section 1
Section Title Page
1 GENERAL PDF  1-1
1.0 Capital Project Process 1-1
1.1 Aesthetics 1-5
1.2 Abutment Plantings 1-11
1.3 Hydrology & Hydraulics
1.3.1   Hydraulic Analysis and Design Reports
1.3.2   Freeboard
1.3.3   Other Design Considerations
1.3.4   Hydraulic and Scour Assessment Reports
1-15
1-15
1-17
1-18
1-18
1.4 Bridge Fencing and Right-Of-Way Fencing
1.4.1   Snow Fencing
1.4.2   Protective Screening
1.4.3   Right-Of-Way Fencing
1-19
1-20
1-20
1-21
1.5 Municipality Coordination and Communication
1.5.1   Project Initiation Letter - (Municipality Coordination)
1.5.2   Municipality Enhancements and Bridge Closures
1.5.3   Maintenance Responsibility
1-24
1-25
1-26
1-27
1.6 Utility Coordination and Communication
1.6.1   Project Initiation Letter - (Utilities)
1.6.2   Occupancy Permits
1.6.3   Thruway Policy on Utility Relocation
1-28
1-30
1-30
1-30
1.7 Horizontal Roadside Clearances
1.7.1   Clear Zone Requirements
1.7.2   Roadside Hazards
1-35
1-36
1-38
1.8 Minimum Bridge Vertical Underclearance for Structures on the Thruway System
1.8.1   Vehicle Structures over the Thruway Mainline and Ramps
1.8.2   Pedestrian and Sign Structures Over the Thruway Mainline and Ramps
1.8.3   Thruway Mainline and Ramp Structures
1-39

1-41
1-41

1-42
1.9 Minimum Clearances at Railroad Tracks
1.9.1   Vertical Underclearances
1.9.2   Horizontal Clearances
1.9.3   Crash Walls
1-42
1-43
1-43
1-44

Section 2
Section Title Page
2 LOADS & RATINGS PDF  2-1
2.1 Design Loads on Structures
2.1.1   Design Live Loads
2.1.2   Design Dead Loads
2.1.3   Design and Future Superimposed Dead Loads
2.1.4   Design Load Table
2.1.5   Moment and Shear Tables on Contract Plans
2-1
2-1
2-5
2-6
2-7
2-8
2.2 Load Rating of Structures 2-10

Section 3
Section Title Page
3 DECK SYSTEMS PDF  3-1
3.0 Thruway Deck Slab and Overlay Policy
3.0.1   New and Replacement Bridges
3.0.2   Rehabilitated Bridges
3.0.3   Future Wearing Surface
3.0.4   Hot Mix Asphalt (HMA) Design and Specification
3-1
3-1
3-2
3-3
3-4
3.1 Cast-In-Place (CIP) Concrete Deck Slabs
3.1.1   Monolithic CIP Concrete Decks
3.1.2 Two-Course Superstructure Decks
3.1.3 Reinforcement in Bridge Decks
3.1.4 Reinforcement in Overhang Regions
3.1.5 Haunches
3.1.6 Forming
3.1.7 Concrete Placement
3-4
3-4
3-16
3-32
3-39
3-63
3-64
3-65
3.2 Prefabricated Deck Systems
3.2.1   Exodermic™ Bridge Deck
3.2.2   INVERSET™ Bridge System
3-73
3-74
3-88
3.3 Concrete Sealants Applied to Structural Decks
3.3.1   Driving and Sidewalk Surfaces
3.3.2   Fascia Surfaces
3-94
3-94
3-94
3.4 Stage Construction
3.4.1   Guidelines for Stage Construction of Deck Slabs on Steel Stringers
3.4.2   Guidelines for Stage Construction of Deck Slabs on Prestressed Concrete Beams
3-95
3-98
3-100
3.5 Shoulder Treatment 3-102
3.6 Bridge Deck Drainage 3-102
3.7 Bridge Deck Access Holes 3-104

Section 4
Section Title Page
4 SUBSTRUCTURES  PDF  4-1
4.1 Foundations
4.1.1   Footings in Rock
4.1.2   Stepped Footings
4.1.3   Design Footing Pressures and Pile Capacities
4.1.4   Piles
4-1
4-3
4-4
4-5
4-7
4.2 Excavation and Backfill
4.2.1   Excavation and Backfill at Structures
4.2.2   Drainage of Backfill
4.2.3   Sheeting and Cofferdams
4.2.4   Tremie Seal
4-10
4-11
4-11
4-14
4-14
4.3 Embankment and Slope Protection
4.3.1   Slope Protection
4.3.2   Berms
4-14
4-15
4-20
4.4 Substructure Materials
4.4.1   Structural Concrete Item for Substructure Concrete
4.4.2   Galvanized Reinforcement in Substructures
4-22
4-22
4-22
4.5 Abutment Features
4.5.1   General
4.5.2   Abutment Stems
4.5.3   Cantilevered Wingwalls (In-Line and Flared)
4.5.4   Free-Standing Wingwalls (In-Line and Flared)
4.5.5   Battered and Stepped Wingwalls
4.5.6   U-Wall Wingwalls
4.5.7   Curved Wingwalls
4.5.8   Other Wingwall Types
4 23
4 23
4-23
4-24
4-25
4-27
4-28
4-28
4-28
4.6 Integral Abutments
4.6.1   Guidelines on Use
4.6.2   Design and Detail Considerations
4.6.3   Integral Abutment Bridge Design Procedures
4-29
4-30
4-32
4-49
4.7 Jointless Bridge Abutments
4.7.1   Guidelines on Use
4.7.2   Design and Detail Considerations
4.7.3   Jointless Bridge Abutment Bridge Design Procedures
4-54
4-56
4-58
4-65
4.8 Semi-Integral Abutments with Curtain Wall Backwalls
4.8.1   Guidelines on Use
4.8.2   Design and Detail Considerations
4.8.3   Semi-Integral Abutment Bridge Design Procedures
4-68
4-69
4-72
4-79
4.9 Conventional Stem Abutments with Bridge Expansion Joints
4.9.1 Guidelines on Use
4.9.2 Design and Detail Considerations
4.9.3 Conventional Abutment Bridge Design Procedures
4-83
4-83
4-88
4-94
4.10 Piers
4.10.1   New Piers
4.10.2   Existing Piers
4-96
4-96
4-105
4.11 Concrete Sealants
4.11.1   Solid Color Protective Concrete Sealer
4.11.2   Clear Penetrating Sealer
4-108
4-108
4-109
4.12 Concrete Joints
4.12.1   Types of Joints
4.12.2   Application of Joints
4-109
4-109
4-110

Section 5
Section Title Page
5 REINFORCEMENT  PDF  5-1
5.1 Galvanized Reinforcement 5-1
5.2 Reinforcement Grade 5-2
5.3 Spacing 5-2
5.4 Cover 5-3
5.5 Maximum Bar Lengths 5-5
5.6 Splicing Reinforcement
5.6.1   General
5.6.2   Splicing Reinforcement in Decks
5.6.3   Splicing Reinforcement in Wall Stems
5.6.4   Splicing Reinforcement in Pier Stems and Columns
5-5
5-5
5-7
5-9
5-10
5.7 Marking of Bars 5-11
5.8 Bar Bending Diagrams & Standard Hooks 5-12
5.9 Drilling and Grouting Reinforcing Bars
5-13
5.10 Minimum Reinforcement Requirements
5.10.1   Footings - Abutments and Piers
5.10.2   Walls, Stems and Solid Piers
5.10.3   Columns
5.10.4   Stirrups and Ties
5-16
5-16
5-17
5-18
5-19
5.11 Reinforcement Development Lengths and Lap Lengths 5-19
5.12 Suggested Reinforcement Placement Details
5.12.1   Design Reinforcement - Spread Footings
5.12.2   Dowel Placement – Footing into Stem
5.12.3   Possible Dowel Combinations
5.12.4   Compression Bars
5-24
5-24
5-26
5-26
5-29

Section 6
Section Title Page
6 PRESTRESSED CONCRETE  PDF  6-1
6.0 Use Criteria 6-1
6.1 Design 6-1
6.2 Width - Box Beams and Slab Beams 6-2
6.3 Camber 6-3
6.4 Diaphragms
6.4.1   Box and Slab Beams
6.4.2   I-Beams
6-3
6-4
6-4
6.5 Transverse Tendons for Box and Slab Beams 6-4
6.6 Concrete Slab for Box and Slab Beams
6.6.1 Slab Reinforcement
6.6.2 Stage Construction Considerations
6-5
6-5
6-6
6.7 Shear Keys 6-7

Section 7
Section Title Page
7 STRUCTURAL STEEL PDF  7-1
7.1 Structural Steel Types
7.1.1   Combinations of Different Types of Structural Steel
7-1
7-1
7.2 Minimum Thickness of Metal 7-2
7.3 Camber
7.3.1   Sag Cambers
7-3
7-4
7.4 Bottom of Slab Elevations 7-5
7.5 Flange Thickness and Width Changes
7.5.1 Flange Thickness Changes
7.5.2 Flange Width Changes
7-6
7-6
7-7
7.6 Designation of Tension Zones 7-7
7.7 Intermediate Stiffeners and Connection Plates
7.7.1   General
7.7.2   Simple Spans
7.7.3   Continuous Spans
7-9
7-9
7-10
7-12
7.8 Longitudinal Stiffeners 7-12
7.9 Bearing Stiffeners
7-12
7.10 Diaphragms & Cross Frames
7.10.1   Diaphragms
7.10.2   Cross Frames
7-13
7-17
7-20
7.11 Lateral Bracing 7-23
7.12 Cover Plates 7-23
7.13 Safety Handrails 7-24
7.14 Drip Bars
7.14.1   Drip Bar Fasteners
7.14.2   Drip Bar Sealing
7-24
7-24
7-25
7.15 Widths of Outstanding Legs of Angles 7-25
7.16 Copes for Framed Connections 7-25
7.17 Minimum Size of Fillet Welds 7-26
7.18 Fasteners
7.18.1   Size of Fasteners (High Strength Bolts)
7.18.2   Spacing of Fasteners
7.18.3   Maximum Spacing of Fasteners
7.18.4   Edge Distance of Fasteners
7-26
7-26
7-27
7-28
7-28
7.19 Field Splices
7.19.1   Welded Field Splices
7.19.2   Bolted Field Splices
7-29
7-29
7-29
7.20 Bearings Welded to Beams or Girders 7-30
7.21 Shear Connectors
7.21.1   Shear Connector Length
7.21.2   Minimum Cover
7.21.3   Shear Connector Diameter
7.21.4   Shear Connector Placement
7.21.5   Design Methods
7.21.6   Sizing Limitation
7.21.7   Shear Connector Spacing and Edge Distance
7-31
7-31
7-34
7-34
7-34
7-34
7-35
7-35
7.22 Unpainted Weathering Steel
7.22.1   Exclusions to Use of Weathering Steel
7.22.2   Use of Weathering Steel
7.22.3   Fasteners for Weathering Steel
7.22.4   Drip Bar Fasteners - Weathering Steel Application
7.22.5   Additional Steel Thickness
7.22.6   Structural Steel Painting at Expansion Joints
7.22.7   Special Notes
7-35
7-36
7-36
7-36
7-37
7-37
7-37
7-37

Section 8
Section Title Page
8 BEARING DEVICES PDF  8-1
8.1 General
8.1.1   Bearing Use Criteria
8.1.2   Bearing Pads
8.1.3   Beveling of Plates
8.1.4   Anchor Bolt Design
8.1.5   Anchor Bolt Hole Edge and End Distance
8-1
8-1
8-2
8-2
8-4
8-10
8.2 Cement Mortar Pads and Plain Elastomeric Pads
8.2.1   Cement Mortar Pads
8.2.2   Plain Elastomeric Pads
8-10
8-11
8-13
8.3 Preformed Fabric Bearings
8.3.1   Preformed Fabric Non-Guided Expansion Bearings
8.3.2   Preformed Fabric Fixed Bearings
8-13
8-13
8-15
8.4 Multi-Rotational (Pot-Type) Bearings
8.4.1   Guided Expansion Pot Bearings
8.4.2   Fixed Pot Bearings
8-16
8-19
8-21
8.5 Multi-Rotational (Disc-Type) Bearings
8.5.1   Guided Expansion Disc Bearings
8.5.2   Fixed Disc Bearings
8-24
8-24
8-27
8.6 Spherical Bearings (Multi-Rotational)
8.6.1   Spherical Guided Expansion Bearings
8.6.2   Spherical Fixed Bearings
8-29
8-29
8-34
8.7 Elastomeric Bearings
8.7.1   Elastomeric Expansion Bearings
8.7.2   Elastomeric Fixed Bearings
8-37
8-37
8-40
8.8 Seismic Isolation Bearings
8-41

Section 9
Section Title Page
9 JOINTS PDF  9-1
9.1 Joint Types 9-1
9.2 Joint Selection Criteria
9.2.1   Cold Poured Joints
9.2.2   Hot Poured Joints
9.2.3   Inflated Neoprene Seal
9.2.4   Preformed Silicone Joint
9.2.5   Strip Seals
9.2.6   Armored Joints
9.2.7   Vermont Joints (Open & Finger)
9.2.8   Modular Joints
9-1
9-3
9-6
9-9
9-11
9-13
9-17
9-17
9-23
9.3 Rail, Barrier, Curbs and Sidewalks
9.3.1   Steel Bridge Rail with Curbs or Sidewalks
9.3.2   Concrete Median or Fascia Barrier
9-27
9-27
9-30
9.4 Snow Plow Angle 9-32

APPENDIX
Appendix Title Page
A EXAMPLE TITLE SHEETS AND TABLES PDF 

EXAMPLE 1. - TITLE SHEET (In-House Design)
EXAMPLE 2. - TITLE SHEET (Consultant Design)
EXAMPLE 3. - TITLE SHEET "Proposal Only" Projects
EXAMPLE 4. – TYPICAL PLAN SHEET BORDER
EXAMPLE 5. - ESTIMATE of QUANTITIES
EXAMPLE 6. – MOMENT, SHEAR, & LOAD TABLES
EXAMPLE 7. - HAUNCH TABLE (New Steel Only)
EXAMPLE 8. - HAUNCH TABLE (Existing Steel Only)
A-1

A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
B NOTES PDF 

A. Introduction
B. Index
C. Notes to be Placed on the General Note Sheet
D. Notes to be Placed in the Body of the Plans

B-1

B-2
B-3
B-GN1-1
B-BP1-1

C

STANDARD DETAILS PDF 

Index

C-1

C-2

D GLOSSARY PDF  D-1
E CHECKLISTS PDF  E-1
F GUIDELINES FOR WELDING STRUCTURAL STEEL FOR BRIDGES PDF  F-1
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