Slide 1

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 2

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 3

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 4

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 5

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 6

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 7

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 8

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 9

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 10

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 11

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 12

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 13

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 14

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us


Slide 15

PennDOT Load Rating of Gusset Plates

GUSSET PLATE EVALUATION
• Tom Macioce, P.E.
• Chief Bridge Engineer

1 of 27
April 2009

www.dot.state.pa.us

PennDOT Load Rating of Gusset Plates
Overview
•
•
•
•
•

PennDOT Gusset Plate Evaluations
PennDOT Inspection Requirements
PennDOT Rating Spreadsheet
Target Dates
Summary

2 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Inventory - 320 steel trusses identified (174
state-owned, 146 locally-owned)
• PennDOT required all deck trusses (54) be reinspected by August 30, 2007, and all non-SD
deck truss bridges by November 30, 2007
• Cost - $2M for the re-inspection of deck trusses
• Cost - $2M for rating of gusset plates

3 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• PennDOT began development of gusset plate
analysis spreadsheet in February 2008
• Permit load analysis approach
– Heavy hauling permits evaluated using Bar 7
– Assume reduced capacity of truss members framing into
gusset plates
– Reduced member capacity approach will be used until
the gusset plate analysis option is incorporated into
BAR7

4 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Spreadsheet development completed in accordance
with FHWA technical advisories- October 2008
• Both LFD and ASD analysis methods supported
• BAR 7 output file load data used in spreadsheet
• Evaluates O.R. only
• 3 man-days to analyze and check a truss bridge
• 1.5 Hours per joint for a standard truss
• 2.5 hour per joint for a complex truss
• Additional hours required for field inspections

5 of 27
www.dot.state.pa.us

PennDOT Truss Gusset Plate Evaluation
• Administration
– Strike Off Letter (431-09-02) issued February 11,
2009
• Updates to Publication 238 Chapters 3 and 6 addressing
gusset plate analysis.
• Developed Deck Truss Geometry Field Inspection Sheet

6 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
• Revised inspection training September 2008
• Issued policy February 2009 Strike-Off Letter

7 of 27
www.dot.state.pa.us

PennDOT Inspection Requirements
Emphasis on• Distortion or bowing
• Corrosion documentation
• Tack weld documentation
• Slippage of connections
• Repairs/retrofits (condition and performance)
• NDE follow-up
• Capture necessary field data to properly load
rate the gusset plate

8 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Annotated data extraction from BAR 7

BAR 7
or
STAAD

Field
Data
Analysis

• Inspection
– Forms
– Digital Photo Measurements

Shop
Drawings

9 of 27
www.dot.state.pa.us

PennDOT Rating Spreadsheet
• Several months to develop
• Tested on 7 bridges, primarily Interstate
bridges
• 5 engineers involved in verification

10 of 27
www.dot.state.pa.us

Target Dates
• Important Milestones • Strike Off Letter (431-09-04) issued March 10,
2009
– State owned bridges analyzed by December 31, 2009
– Local owned bridges analyzed by December 31, 2010.

• Revise BAR7 to include gusset plate analysis
December 2009

11 of 27
www.dot.state.pa.us

Status of Analysis
• Districts to provide monthly status reports for
tracking progress
• State - 183
– Completed 54
– Under Analysis 98
– Future Work Orders 31

• Local - 149
– Completed 52
– Under Analysis 11
– Future Work Orders 86

12 of 27
www.dot.state.pa.us

Issues
• Continuous chord members through gusset plate
• Welded connections
– Plates are analyzed for shear
– Weld strengths analyzed by supplemental hand
calculations

• QA reviews of analysis is required
• 1 bridge has required posting due to gusset plate
rating
– Deck Truss
– Bearing location
– Section loss along top chord
• Leaking deck joint
13 of 27
www.dot.state.pa.us

Summary
• Evaluation will provide additional level of bridge
safety
• FHWA Technical Guidance is appropriate
• Elected to perform rating as opposed to a
screening process
• Revise BAR7 to include gusset plate analysis
December 2009

14 of 27
www.dot.state.pa.us

Thank You
15 of 27
www.dot.state.pa.us