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Washington State Department of Transportation

BridgeDesignManualM 23-50

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Washington State Department of Transportation

BridgeDesignManualM 23-50

Chapters 1-7

Program Development DivisionBridge and Structures


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Engineering PublicationsWashington State Department of Transportation

PO Box 47408

Olympia, WA 98504-7408

E-mail: [email protected]

Phone: (360) 705-7430

Fax: (360) 705-6861

http://www.wsdot.wa.gov/fasc/EngineeringPublications/

Persons with disabilities may request this information be prepared and supplied in

alternate forms by calling the WSDOT ADA Accommodation Hotline collect

(206) 389-2839. Persons with hearing impairments may access WA State

Telecommunications Relay Service at TT 1-800-833-6388, Tele-Braille 1-800-833-6385,

or Voice 1-800-833-6384, and ask to be connected to (360) 705-7097.


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Foreword

This manual has been prepared to provide Washington State Department of Transportation (WSDOT) bridgedesign engineers with a guide to the design criteria, analysis methods, and detailing procedures for the preparationof highway bridge and structure construction plans, specifications, and estimates.

It is not intended to be a textbook on structural engineering. It is a guide to acceptable WSDOT practice. Thismanual does not cover all conceivable problems that may arise, but is intended to be sufficiently comprehensive to,

along with sound engineering judgment, provide a safe guide for bridge engineering.

A thorough knowledge of the contents of this manual is essential for a high degree of efficiency in the engineeringof WSDOT highway structures.

This loose leaf form of this manual facilitates modifications and additions. New provisions and revisions will be

issued from time to time to keep this guide current. Suggestions for improvement and updating the manual arealways welcome.

All manual modifications must be approved by the Bridge Design Engineer.

__________________________________________M. MYINT LWINBridge and Structures EngineerWashington State Department of Transportation

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BRIDGE DESIGN MANUAL

Criteria

General Information Contents

Page

1.1 Manual Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.3 Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

C. Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1.4 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

A. Manual Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

B. Bridge Design Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

C. Record of Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Bridge and Structures Office Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2-1

1.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2.2 Organizational Elements of the Office . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. Bridge and Structures Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B. Bridge Design Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

C. Bridge Preservation Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

D. Bridge Management Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

E. Computer Applications Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

F. Consultant Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

G. Architect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

H. Staff Support Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

I. Office Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Design Procedures and Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3-1

1.3.1 Design/Check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. WSDOT PS&E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Consultant PS&E Projects on WSDOT Right of Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C. Consultant PS&E On County and City Right of Way Projects . . . . . . . . . . . . . . . . . . . . . . 6

1.3.2 Design/Check Calculation File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

A. File of Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

B. Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

C. To Be Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

D. Not to Be Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

E. Upon Completion of the Design Work, Fill Out a Design Completion Checklist . . . . . . . . . . 8

1.3.3 Office Copy Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3.4 Addenda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3.5 Shop Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A. Bridge Shop Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

B. Sign Structure, Signal, and Illumination Shop Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3.6 Contract Plan Changes (Change Orders and As-Builts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Request for Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

B. Processing Contract Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.4 Coordination With Other Divisions and Agencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4-1

1.4.1 Preliminary Planning Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.4.2 Final Design Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. Coordination With Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Technical Design Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.5 Bridge Design Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5-1

1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.5.2 Preliminary Design Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.5.3 Final Design Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

A. Breakdown of Project Man-Hours Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Estimate Design Time Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

C. Monthly Project Progress Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 Guidelines for Bridge Site Visits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6-1

1.6.1 Bridge Rehabilitation Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.6.2 Bridge Widenings and Seismic Retrofits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.6.3 Rail and Minor Expansion Joint Retrofits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.6.4 New Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.6.5 Bridge Demolition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.99 Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.99-1

Appendix A Design Aids

1.3-A1 Standard Design Criteria Form

1.3-A2 Exceptions to the Standard Design Criteria Form

1.3-A3 Design Completed Checklist

1.3-A4 Job File Table of Contents

1.3-A5 Office Time Report

1.3-A6 Not Included in Bridge Quantities List

1.3-A7 Special Provisions Checklist1.5-A1 Breakdown of Project Manhours Required Form

1.5-A2 Monthly Project Progress Report Form

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Structural Steel Manual Description

1.1 Manual Description

1.1.1 Purpose

This manual is intended to be a guide for Bridge Designers and others involved with bridge design for

the Washington State Department of Transportation (WSDOT). It contains design details and methodsthat have been standardized and it interprets the intent of specifications. It is not intended to govern design

in unusual situations nor to unduly inhibit the designer in the exercise of engineering judgment. There is

no substitute for good judgment. The following axioms are given as a reminder that simple things make

a big difference.

1. Gravity always works if something is not supported, it will fall.

2. A chain reaction will cause small failures to become big failures, unless alternate load paths are

available in the structure (i.e., progressive collapse).

3. Small errors, such as a drafting error or a misplaced decimal, can cause large failures.

4. Vigilance is needed to avoid small errors. This applies to construction inspection as well as in the

design phase.

5. A construction job should be run by one person with authority, not a committee. It has been said that

a camel is a horse designed and built by a committee.

6. High quality craftsmanship must be provided by everyone.

7. An unbuildable design is not buildable. An obvious fact often overlooked by the architect or

structural designer. Think about how forms will be built, then removed if necessary.

8. There is no foolproof design.

9. The best way to ensure a failure is to disregard or ignore lessons from past failures.

10. Many problems can be avoided by using a little loving care.

1.1.2 Specifications

The AASHTO publications Standard Specifications for Highway Bridges andLRFD Bridge Design

Specifications are the basic documents guiding the design of highway bridges and structures. This

WSDOTBridge Design Manual is intended to supplement AASHTO and other specifications by provid-

ing additional direction, design aids, examples, and information on office practices. Where conflicts exist

between this manual and the AASHTO Standard Specifications, this manual will control. When a conflict

exists that is not resolved within the manual, further guidance shall be obtained from the Bridge Design

Engineer or his representative.

The AASHTO publications are not duplicated in this manual. Appropriate specifications and other

references are listed in Section 1.99.

1.1.3 Format

A. General

TheBridge Design Manual consists of two volumes with each chapter organized as follows:

Criteria or other information

Appendix A (printed on yellow paper) Design Aids

Appendix B (printed on salmon paper) Design Examples

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B. Chapters

1. General Information

2. Preliminary Design

3. Analysis

4. Loads

5. Reinforced Concrete Superstructures

6. Prestressed Concrete Superstructures

7. Structural Steel

8. Miscellaneous Design

9. Substructure Design

10. Detailing Practice

11. Quantities

12. Construction Costs

13. Construction Specifications

14. Inspection and Rating

C. Numbering System

1. The numbering system for the criteria consists of a set of numbers followed by letters as required

to designate individual subjects. This format is similar to that used by AASHTO.

Example:

5.0 Reinforced Concrete Superstructures (Chapter)

5.4 Box Girder Bridges (Section)

5.4.2 Girder (Subsection)

C. Shear Resistance

1. The Shear Diagram

a. Shear Reinforcement

(1) Placement

2. Numbering of Sheets

Each section starts a new page numbering sequence. The page numbers are located in the loweroutside corners and begin with the chapter number, followed by the section number, then a

sequential page number.

Example: 5.4-1, 5.4-2, etc.

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3. Appendices are included to provide the designer with design aids (Appendix A) and examples

(Appendix B). Design aids are generally standard in nature, whereas examples are modified to

meet specific job requirements.

An appendix is numbered using the chapter followed by section number and then a hyphen and

the letter of the appendix followed by consecutive numbers.

Example: 5.4-A1 (Box Girder Bridges) designates a design aid required or useful to accomplish

the work described in Chapter 5, Section 4.

4. Numbering of Tables and Figures

Tables and figures shall be numbered using the chapter, section, subsection in which they are

located, and then a hyphen followed by consecutive numbers.

Example: Figure 5.4.2-1 is the first figure found in Chapter 5, section 4, subsection 2.

1.1.4 Revisions

A. Manual Updates

TheBridge Design Manual will change as new material is added and as criteria and specifications

change.

Revisions and new material will be issued with a Publications Transmittal Form. The form will have

a revision number and remarks or special instructions regarding the sheets. The revision number shall

be entered on the Record of Revision sheet in this manual. This allows the user to verify that the

manual is up to date.

B. Bridge Design Instruction

Special instructions regarding interpretation of criteria or other policy statements may be issued using

a Bridge Design Instruction (BDI). The BDI will be transmitted in the same manner as outlined above

for manual revisions. The BDI should be inserted in the appropriate place in the manual and remainsin effect until the expiration date shown or until superseded by a revision to the manual. A sample

BDI is shown on Figure 1.1.4-1.

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February 1997

BRIDGE DESIGN INSTRUCTION 5.1.1 CHAPTER 5

SUBJECT: Use of Concrete Class 5000 and Class 4000D

ACTION: Place this instruction in your manual and note the instruction number in your

Record of Manual Revisions, 1.1.4.

TEXT There is confusion regarding the availability of Concrete Class 5000. This

class of concrete is available within a 30-mile radius of Seattle, Spokane and

Vancouver, Washington. Available means that there are concrete suppliers

in these urban areas capable of supplying Concrete Class 5000 in accordance

with WSDOT specifications. Outside this 30-mile radius (or near the fringe),

the concrete suppliers generally do not have the quality control procedures

and expertise to supply this higher strength concrete. The Construction Office

or Materials Lab should be contacted for availability for project sites outside

these areas.

In general, Class 4000D Concrete would be specified for bridge roadway decks

outside this 30 mile radius. Class 4000D Concrete specifications require a

14-day wet cure and flyash as an additive. Typically, Class 4000 Concrete would

be specified for other bridge concrete members above ground. This mix wasdeveloped by the Materials Lab to be at least as durable as Class 5000 Concrete.

By utilizing the above guidelines, WSDOT will receive the most durable bridge

deck at the least cost.

Approved: _________________________

C. C. Ruth

Bridge Design Engineer

CCR/dbRTS

Figure 1.1.4-1

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C. Record of Manual Revisions

In order that a ready means be available to check whether a manual is up to date, each manual holder

is requested to keep his copy up to date and to record Bridge Design Instructions or Revisions as

material is added or changed. The form below is intended for use in keeping this record. At any time,

a manual holder will be able to check his list with the list in the master manual.

Revision Entry By Revision Entry By Revision Entry By

Number Date (Initial) Number Date (Initial) Number Date (Initial)

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General Information Bridge and Structures Office Organization

1.2 Bridge and Structures Office Organization

1.2.1 General

The document defining the responsibilities for bridge design within the Washington State Department of

Transportation (WSDOT) is the Organization Handbook. In that document, the responsibilities of theBridge and Structures Office are stated as follows:

Provides structural engineering services for the department. Provides technical advice and assistance

to other governmental agencies on such matters.

The WSDOTDesign Manual states the following:

Bridge design is the responsibility of the Bridge and Structures Office in Olympia. Any design

authorized to be performed at the regional level is subject to review and approval by the Bridge

and Structures Office.

1.2.2 Organizational Elements of the Office

A. Bridge and Structures Engineer

Responsible for structural engineering services for the department. Manages staff and programs for

structure design, contract plan preparation, and inspections and assessments of existing bridges.

B. Bridge Design Engineer

The Bridge Design Engineer is directly responsible to the Bridge and Structures Engineer for

structural design and review, and advises other divisions and agencies on such matters.

1. Structural Design Units

The Structural Design Units are responsible for the final design of bridges and other structures.

Final design includes preparation of plans. The units provide special design studies, develop

design criteria, check shop plans, and review designs submitted by consultants.

Each design unit normally consists of individuals including a section supervisor and a bridge

specialist. Organization and job assignments within the unit are flexible and are related to the

projects underway at any particular time as well as to the qualifications of individuals. The

emphasis in the design sections is on providing sound designs, checking, reviewing, and

detailing in an efficient manner.

A bridge specialist is assigned to each design unit. Each specialist has a particular area of

responsibility. The three areas are concrete, steel, and expansion joints and bearings. The

specialist acts as a resource person for the bridge office in his specialty and is responsible for

keeping up-to-date on current AASHTO criteria, new design concepts, technical publications,

construction and maintenance issues.

The design units are also responsible for the design and preparation of contract plans formodifications to bridges in service. These include bridge rail replacement, deck repair, seismic

retrofits, emergency repairs when bridges are damaged by vehicle or ship collision or natural

phenomenon, and expansion joint and drainage retrofit. They review proposed plans of utility

attachments to existing bridges.

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2. Bridge Projects Unit

The Bridge Projects Engineer directs preliminary design work, specification and cost estimates

preparation, falsework review, and coordinates scheduling of bridge design projects with the

Bridge Design Engineer and the Design Unit Supervisors.

The Preliminary Design engineers are responsible for bridge project planning from design studies

to preliminary project reports. They are responsible for preliminary plan preparation of bridge

and walls including assembly and analysis of site data, preliminary structural analysis, cost

analysis, determination of structure type, and drawing preparation. They also review highway

project environmental documents and design reports and handle Coast Guard liaison duties.

The Specifications and Estimate (S&E) engineers develop and maintain construction

specifications and cost estimates for bridge projects originating in the Bridge and Structures

Office. They also review the specifications and cost estimates for bridge contracts prepared by

consultants and other government agencies which are administered by WSDOT. They assemble

and review the completed bridge PS&E before submittal to the Plans Branch. They also coordi-

nate the PS&E preparation with the regions, Plans Branch, and maintain bridge constructioncost records.

The Construction Support engineers are responsible for checking the contractors falsework,

shoring, and form plans. Shop plans review and approval are coordinated with the design

sections. Actual check of the shop plan is done in the design section. Field requests for plan

changes come through this office for a recommendation as to approval. As built plans are

prepared by this unit at the completion of a contract.

The Scheduling Engineer monitors the design work schedule for the Bridge and Structures Office

and maintains records of bridge contract costs.

In addition, the unit is responsible for theBridge Design Manual, design standards, professional

activities, and AASHTO support.

C. Bridge Preservation Engineer

Directs activities and develops programs to assure the structural and functional integrity of all state

bridges in service. Directs emergency response services when bridges are damaged.

1. Bridge Preservation Unit

The Bridge Preservation Unit is responsible for planning and implementation of an inspection

program for the more than 3,000 fixed and movable state highway bridges. In addition, the unit

provides inspection services on some local agency bridges and on the states 21 ferry terminals.

All inspections are conducted in accordance with the National Bridge Inspection Standards

(NBIS).

The unit maintains a statewide computer inventory Washington State Bridge Inventory System(WSBIS), of current information on more than 7,300 state, county, and city bridges in accordance

with the NBIS. This includes load ratings for all bridges. It prepares aBridge Listof the states

bridges which is published every two years.

The unit is responsible for the bridge load rating and risk reduction (SCOUR) programs. It

provides damage assessments and emergency response services when bridges are damaged or

lost due to vehicle or ship collision or natural phenomenon such as floods, wind, or earthquakes.

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D. Bridge Management Engineer

This Bridge Management Unit is responsible for program development, planning, and monitoring of

all H-Program activities. These include HBRRP funded bridge replacements and rehabilitation, bridge

deck protection, major bridge repair, and bridge painting.

In addition, this unit manages the bridge deck protection program including the deck testing program

and the bridge research program. It is responsible for the planning, development, coordination, and

implementation of new programs (e.g., Seismic Retrofit and Preventative Maintenance), experimental

feature projects, new product evaluation, and technology transfer.

E. Computer Applications Engineer

The Computer Support Unit is responsible for computer resource planning and implementation,

computer user support, liaison with Management Information Systems (MIS), and computer aided

engineer operation support. In addition, the unit is responsible for Standard Plan updates.

F. Consultant Coordinator

The Consultant Coordinator prepares bridge consultant agreements and coordinates consultant PS&Edevelopment activities with those of the department.

G. Architect

The Principal Architect is responsible for approving preliminary plans, preparing renderings, model

making, and other duties to improve the aesthetics of our bridges and other structures. The Principal

Architect works closely with staff and regions. During the design phase, designers should get the

Architects approval for any changes to architectural details shown on the approved preliminary plan.

H. Staff Support Unit

The Staff Support Unit is responsible for many support functions, such as: typing, timekeeping,

payroll, receptionist, vehicle management, mail, inventory management, and other duties requested

by the Bridge and Structures Engineer. Other duties include: of field data, plans for bridges undercontract or constructed, and design calculations. This unit also maintains office supplies and provides

other services.

I. Office Administrator

The Office Administrator is responsible for coordinating personnel actions, updating the

organizational chart, ordering technical materials, and other duties requested by the Bridge

and Structures Engineer. Staff development and training are coordinated through the Office

Administrator. Logistical support, office and building maintenance issues are also handled by

the Office Administrator.

July 2000 1.2-3


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1.2.3 Design Unit Responsibilities and Expertise

The following is an updated summary of design responsibilities/expertise within the Bridge Design

Section. Contact the unit manager for the name of the appropriate staff expert for the needed specialty.

Unit Manager Responsibility/Expertise

K. N. Kirker Expansion Joint Modifications

Retaining Walls (including MSE, Tie-Back, and Soil Nail)

Seismic Retrofit

Y. A. Mhatre Noise Walls

Bridge Traffic Barriers

Standard Plans for Prestressed Concrete

R. T. Shaefer Coast Guard Permits

Cost Estimates

Standard Plans (other than Prestressed Concrete)

Bridge Design ManualJ. A. VanLund Sign Supports, Light Standards, Traffic Signal Supports

Repairs to Damaged Prestressed Girder Bridges

P. T. Clarke Floating Bridges

Special Structures

P65:DP/BDM1

1.2-4 July 2000


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General Information Design Procedures and Processes

July 2000 1.3-1

1.3 Quality Control/Quality Assurance (QC/QA) Process for WSDOT Bridge Designs

1.3.0 General

A. The QA/QC process for bridge designs is a critical element of quality structure plan preparation.

The overall goals of the structural design process are:

The structural design maximizes the safety of the traveling public and is in accordance with

State Law.

The structural design is in accordance with the WSDOT Bridge Design Manual, AASHTO

Bridge Design Specifications, good structural engineering practice, and geometric criteria

provided by the Region.

Designed structures are durable, low-maintenance, and inspectable.

The structural design facilitates constructibility and minimizes overall construction costs, while

exhibiting a pleasing architectural style.

The structural design contract documents are produced in accordance with customers needs

(schedule, construction staging, and available program funding).

Structural design costs are minimized.

A well-organized and readable structure calculation record is produced.

Plan quality is maximized.

Design process allows for change, innovation, and continuous improvement.

The overall goals are listed in order of importance. If there is a conflict between goals, the more

important goal takes precedence.

The design unit manager determines project assignments and the QC/QA process to be used in

preparation of the structural design. The intent of the QC/QA process is to facilitate production

efficiency and cost-effectiveness while assuring the structural integrity of the design and maximizing

the quality of the structure contract documents.

1.3.1 Design/Check Procedures

A. PS&E Prepared by WSDOT Bridge and Structures Office

1. Design Team

The design team, consisting of the Designer(s), Checker(s), Structural Detailer(s), and Specifica-

tion and Estimate engineer are responsible for preparing a set of contractible, clear, and concise

structural contract documents by the scheduled date and within the workforce hours allotted for

the project. On large projects, the design unit manager may assign a designer additional duties

as a Design Team Leader to assist the manager in planning, coordinating, and monitoring theactivities of the design team. In this case, the team leader would also coordinate with the Region

and the Geotechnical Branch.

The QC/QA process will likely vary depending on the type and complexity of the structure being

designed, and the experience level of the design team members. More supervision, review, and

checking are required when the design team members are less experienced. In general, it is good

QC/QA practice to have some experienced members on each design team. All design team

members should have the opportunity to provide input for maximizing the quality of the design

being produced.


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2. Designer Responsibility

The designer is responsible for the structural analysis, completeness, correctness, and quality

of the plans. The designer shall provide quality control in the process of plan preparation. That

is, errors and omissions need to be caught and corrected before subsequent checking and review

of plans. A good set of example plans to follow, representative of bridge type, is indispensable

in this regard.

During the design phase of a project, the designer will need to communicate with other

stakeholders. This includes acquiring, finalizing or revising roadway geometrics, soil reports,

hydraulics recommendations, and utility requirements. Constructibility issues may also require

that the designer communicate with the Region or Construction Office. The bridge plans must

be coordinated with the PS&E packages produced concurrently by the Region.

The designer or team leader is responsible for project planning which involves the following:

a. Prepare a Design Time Estimate Bar Chart (see Section 1.5.2).

b. Identify tasks and plan order of work.c. Prepare design criteria, which should be included in the design calculations. Use Standard

Design Criteria Form, 1.3-A1-1 for routine projects. A project specific design criteria should

be made when appropriate. Compare tasks with BDM office practice and AASHTO bridge

design specifications.

(1) Sufficient guidelines?

(2) Deviation from BDM/AASHTO?

(3) Any question on design approach?

(4) Deviation from office practices regarding design and details?

(5) Other differences.d. Meet with the Region design staff and other project stakeholders early in the design process

to resolve as many issues as possible before proceeding with final design and detailing.

e. Identify coordination needs with other designers, units, and offices.

f. Early in the project, determine the number and titles of sheets. For projects with multiple

bridges, each set of bridge sheets should have a unique set of bridge sheet numbers.

The bridge sheet numbering system should be coordinated with the Region design staff.

g. At least monthly or as directed by the design unit manager:

(1) Update Project Schedule and List of Sheets.

(2) Estimate percent complete.(3) Estimate time to complete.

(4) Work with design unit manager to adjust resources, if necessary.

h. Develop preliminary quantities for 90 percent complete cost estimate.


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i. Near end of project:

(1) Keep track of sheets as they are completed.

(2) Develop quantities and special provisions checklists that are to be turned in with

the plans.

(3) Prepare Bar List.

(4) Enter information into the Bridge Design Record.

(5) Coordinate all final changes, including review comments from the checker, managers,

specialists, the Region, and the Construction Office.

(6) Meet with Region design staff and other project stakeholders at the constructibility

meeting to address final project coordination issues.

The designer shall advise and get the design unit managers approval whenever details

deviate from the BDM office practice and AASHTO Bridge Design Specifications. The

designer shall provide documentation of the structural design deviations in the calculations.

The designer should inform the design unit manager of any areas of the design which should

receive special attention during checking and review.

The design calculations are prepared by the designer and become a very important record

document. Design calculations will be a reference document during the construction of the

structure and throughout the life of the structure. It is critical that the design calculations be

user friendly. The design calculations shall be well organized, clear, properly referenced,

and include numbered pages along with a table of contents. The design calculations shall

be archived. Computer files should be archived for use during construction, in the event that

changed conditions arise. Archive-ready design and check calculations shall be bound and

submitted to the design unit manager within 30 days of submitting the 100 percent PS&E.

Calculations shall be stored in the design unit until completion of construction. Afterconstruction, they shall be sent to archives.

The designer is also responsible for resolving construction problems referred to the Bridge

Office during the life of the contract. These issues will generally be referred through the

Bridge Technical Advisor, the design unit manager, the Construction Support Unit, or the

OSC Construction Unit.

3. Design Checker Responsibility

The checker is responsible to the design unit manager for quality assurance of the structural

design, which includes checking the design and plans to assure accuracy and constructibility.

The design unit manager works with the checker to establish the level of checking. The checking

procedure for assuring the quality of the design will vary from project to project. Following are

some general checking guidelines:

a. Design Calculations

(1) For designs checked by an experienced checker, a review and initialing of the designers

calculations by the checker is acceptable. If it is more efficient, the checker may choose

to perform his/her own calculations to check. All the designer and checker calculations

shall be placed in one design calculation set.


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(2) For designs checked by an inexperienced checker, a more thorough check should be

performed by the checker to enhance his/her understanding of structural design. In this

case, the design unit manager should provide the checker with a design example.

(3) Revision of design calculations, if required, is the responsibility of the designer.

b. Structural Plans

(1) The checkers plan review comments are recorded on the structural plans, including

details and bar lists, and returned to the designer for consideration. If the checkers

comments are not incorporated, the designer should provide justification for not doing

so. If there is a difference of opinion that cannot be resolved between the designer and

checker, the unit manager shall resolve the issue.

(2) If assigned by the design unit manager, the checker shall perform a complete check of

the geometry using CADD, hand calculations, or a geometric program.

(3) Revision of plans, if required, is the responsibility of the designer.

4. Structural Detailer Responsibility

The structural detailer is responsible for the structural plan sheets. The plans shall be neat,

correct, and easy to follow and drawn to scale. The structural detailer may also assist the designer

and design checker in such areas as determining control dimensions and elevations, geometry,

and calculating quantities.

Some detailing basics and principles:

a. Refer to BDM, Chapter 10, for detailing practices.

b. Provide necessary and adequate information. Try to avoid repetition of information.

c. Avoid placing too much information into any one sheet.

d. Plan sheets should detailed in a consistent manner and follow accepted detailing practices.

e. Provide clear and separate detail of structural geometrics. Use clear detailing such as stand

alone cross sections or a framing plan to define the structure.

f. Avoid reinforcing steel congestion.

g. Check reinforcement detail for consistency. Beware of common mistakes about placement

of stirrups and ties (such as: stirrups too short, effect of skew neglected, epoxy coating not

considered, etc.). Check splice location and detail, and welding locations.

h. Use cross references properly.

i. Use correct and consistent terminology. For example, the designation of Sections, Views,

and Details.j. Check for proper grammar and spelling.

k. On multiple bridge contracts, the structural detailing of all bridges within the contract shall

be coordinated to maximize consistency of detailing from bridge to bridge. Extra effort

will be required to assure uniformity of details, particularly if multiple design units and/or

consultants are involved in preparing bridge plans. This is a critical element of good quality

bridge plans.


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l. Refer to the Bridge Book of Knowledge for current special features and details used on

other projects.

5. Specialist Responsibility

There are currently four specialist positions in the Bridge and Structures Office. There is aspecialist assigned to each of the three design sections and one to the Bridge Preservation

Section. The primary responsibility of the specialist is to act as a knowledge resource for this

office. The Specialists maintain an active knowledge of their specialty area along with a current

file of products and design procedures. Proactive industry contacts are maintained by the Special-

ists. Specialists also provide training in their area of specialty. As contract plans are prepared by

other designers, the Specialists are expected to review and initial drawings covered by their

specialty area. Plans produced directly by Specialists in their specialty area should be prepared

with their own stamp and signature. Specialists also assist the Bridge Engineer in reviewing and

voting on amendments to AASHTO specifications. They also are responsible for keeping their

respective chapters of the Bridge Design Manual up to date. The secondary responsibility of the

Specialist is to serve as design section supervisor when the supervisor is absent.

There are three specialty areas in the Design Section: Concrete, Expansion Joints and Bearings,

and Steel.

6. Design Unit Technical Responsibilities

Each Design Unit is responsible for maintaining a resource of technical knowledge and leader-

ship. As described in the previous Section (5.), each unit has a Design Specialist (Concrete, Steel,

Expansion Joints and Bearings). In addition, each Design Unit maintains a resource of technical

knowledge in several technical areas. Following, is a list of all technical subjects for which a

resource is maintained:

Coast Guard Permits

Cost Estimates Bridge Special Provisions

Sign Supports, Light Standards, Traffic Signal Supports

Repairs to Damaged Prestressed Girders

Expansion Joint Modifications

Retaining Walls (Including MSE, Tie-Back, and Soil Nail)

Seismic Retrofit

Noise Walls

Traffic Barrier Retrofits/Standards Bridge Standard Plans (BDM)

The resource/leadership responsibility for these technical areas does not necessarily include

responsibility for performing all of the work relating to the technical area. For many of the

technical areas, the Design Unit acts as a resource for the technical area, only, and as a contact

for industry and stakeholders.


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7. Specification and Estimating Engineer Responsibilities

The S&E Engineer is responsible for compiling the PS&E package for bridge and/or related

highway structural components. This PS&E package includes Special Provisions (BSPs and

GSPs as appropriate), construction cost estimate, construction working day schedule, test hole

boring logs and other appendices as appropriate, and the design plan package.

The S&E Engineer begins work after the design unit submits copies of the 90 percent design

plans. This normally occurs on or before the date specified in the Bridge Design Schedule.

A set of quantities, a copy of the Not Included in Bridge Quantities, and a S&E Checklist

are included in the PS&E package.

As a first order of business, the S&E Engineer distributes the 90 percent design plans for review

by the Region and other offices. While other offices are reviewing the plan package, the S&E

Engineer attends to the following duties.

Review the job file, foundation report, and design plans to make sure that materials specified

in the plans are consistent with the current Standard Specifications.

Check the plans for engineering accuracy, completeness, and constructibility.

Create a run list of BSPs, GSPs, and appropriate Standard Specification amendments.

Compile a cost estimate file using the quantities submitted by the designers and current Unit

Cost figures for the various materials used in the bridge.

The S&E Engineer develops a construction working day schedule which is also based on the

quantities submitted by the designers.

At the same time, the S&E Engineer coordinates the Bridge and Structures Office review of the

Review PS&E and responds with comments to the Region. The S&E Engineer also receives all

Region review comments and distributes them to the appropriate designer for action. The S&E

Engineer also participates in the Region Review Roundtable Meeting. After the ReviewRoundtable Meeting, all comments are addressed by the designers.

The S&E Engineer has the following responsibilities during coordination of the Final Bridge

PS&E turn in.

Make Special Provision reviews to the Bridge Special Provision word file.

Inform the appropriate Region PS&E contact when the word file is complete and ready for

transfer.

Complete Cost Estimate and Quantity revisions to the cost estimate files.

Electronically distribute all cost estimate file revisions to the appropriate Region PS&E

contact.

Once the final Bridge Sheet mylars are printed, stamped, and signed, the S&E Engineer arranges

for 11 by 17 paper prints for submittal to the appropriate Region PS&E contact. The original

stamped and signed mylars are turned in to the Construction Plans Unit for storage.

During the Advertising period many questions are funneled into the Bridge Office by the Project

Engineers and the communications are generally distributed to the S&E Engineer. The S&E

Engineer will ascertain the query, answer the question from the Contractors, or seek advice or

help from the design engineer. The S&E Engineer will then respond back to the PE. Revisions

to the Plans or Specs are sometimes needed as a result of these questions from Contractors.


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Addendums are created to augment the original advertised document to make sure all

Contractors are advised prior to Bid Openings. These Addendums are coordinated with the

Region and OSC Plans.

The S&E Engineer attends the award meetings to justify bids and advise whether or not to award

the contract.

Other responsibilities included are:

Special Provisions and Estimates for Change Order Work

Cost estimates in the scoping stage of a project

Working Day information during Stage Construction planning

Initiates/Coordinates Amendment and GSP Updates

Maintains BSP Library

8. Design Unit Manager Responsibility

a. The design unit manager is responsible to the Bridge Design Engineer for the timely

completion and quality of the bridge plans.

b. The design unit manager works closely with the design team (designer, checker, and

structural detailer) during the design and plan preparation phases to help avoid major

changes late in the design process. Activities during the course of design include:

(1) Evaluate the complexity of the project and the designers skill and classification level

to deliver the project in a timely manner. Determine both the degree of supervision

necessary for the designer and the amount of checking that will be required by the

checker.

(2) Assist the design team in defining the scope of the project, identifying the tasks to be

accomplished, developing a project work plan and schedule, and assigning resources toachieve delivery of the project.

(3) Review and approve design criteria before start of design.

(4) Help lead designer conduct face-to-face project meetings, such as: project kick-off

and wrap-up meetings with Region, geotechnical staff, bridge construction, and

consultants to resolve outstanding issues.

(5) Assist the design team with planning, anticipating possible problems, collectively

identifying solutions, and facilitating timely delivery of needed information, such as

geometrics, hydraulics, foundation information, etc.

(6) Interact with design team regularly to discuss progress, problems, schedule, analysis

techniques, constructibility and design issues. Always encourage forward thinking,innovative ideas and suggestions for quality improvement.

(7) Arrange for and provide the necessary resources and tools for the design team to do the

job right the first time. Offer assistance to help resolve questions or problems.

(8) Help documentand disseminate information on special features and lessons learned for

the benefit of others and future projects.


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(9) Mentor and train designers and detailers on state-of-the-art practices and through the

assignment of a variety of structure types.

c. The design unit manager works closely with the design team during the plan review phase.

Review efforts should concentrate on reviewing the completed plan details and design

calculations for completeness and for agreement with office criteria and practices. Review

the following periodically and at the end of the project:

(1) Design Criteria

Seismic a value

Foundation report recommendations, selection of alternates

Deviations from AASHTO, BDM, Documentation

(2) Design Time

d. Review designers estimated time to complete the project. Plan resource allocation to

complete the project to meet the scheduled Ad Date. Monitor monthly time spent on theproject. Prepare and submit to the Bridge Projects Engineer monthly time reports for each

project. Estimate time remaining to complete project, percent completed, and whether

project is on or behind schedule. Arrange and plan resources to ensure a timely delivery

of the project within the estimated time to complete the project.

e. Advise Region of project scope and cost-creep. Use quarterly status reports to update Region

and Bridge Projects Engineer.

f. Useappropriate computer scheduling software or other means to monitor time usage and to

allocate resources and to plan projects.

g. Fill out Office Time Report (see Appendix 1.3-A5).

h. Review of constructibility. Any problems unique to the project?i. Check the final plans for the following:

(1) Scan the job file for unusual items relating to geometrics, hydraulics, geotechnical,

environmental, etc.

(2) Overall check/review of sheet #1, the bridge layout for:

Consistency especially for multiple bridge project

Missing information

(3) Check footing layout for conformance to Bridge Plan and for adequacy of information

given. Generally, the field personnel should be given enough information to layout

the footings on the ground without referring to any other sheets. Details should be clear,precise, and dimensions tied to base reference such as survey line or defined center line

of bridge.

(4) Check the sequence of the plan sheets. They should adhere to the following order:

layout, footing layout, substructures, superstructures, miscellaneous details, barriers,

and bar list. Also check for appropriateness of the titles.


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(5) Check overall dimensions and elevations, spot check for compatibility. For example,

check compatibility between superstructures and substructure. Also spot check bar

marks.

(6) Use ones training, common sense, and experience to size-up structural dimensions

and reinforcement, etc., for structural adequacy. When in doubt, prepare for a line of

questioning to the designer/checker.

j. Stamp and seal the plans.

9. Bridge Design Engineers Responsibilities

The Bridge Design Engineer is the coach, mentor, and facilitator for the WSDOT QC/QA Bridge

Design Process. The leadership and support provided by this position is a major influence in

assuring bridge design quality for structural designs performed by both WSDOT and consultants.

The following summarizes the responsibilities of the Bridge Design Engineer relative to QC/QA:

a. When the structural contract plans are sealed by the Bridge Design Engineer, a structural/

constructibility review of the plans is performed. This is a quality assurance (QA) functionas well as meeting the responsible charge requirements of the laws relating to Professional

Engineers.

b. Review and approve the Preliminary Bridge Plans. The primary focus for this responsibility

is to assure that the most cost-effective and appropriate structure type is selected for a

particular bridge site.

c. Participate in coordination, scheduling, and project-related discussions with stakeholders,

customers, and outside agencies relating to major structural design issues.

d. Facilitate resolution of major project design issues.

e. Review unique project special provisions and major Standard Specification modifications

relating to structures.f. Facilitate partnerships between WSDOT, consultant, and construction industry stakeholders

to facilitate design quality.

g. Encourage designer creativity and innovation.

h. Exercise leadership and direction for maintaining a progressive and up to date Bridge Design

Manual.

i. Create an open and supportive office environment in which Design Section staff are empow-

ered to do high quality structural design work.

10. General Bridge Plan Signature Policy

The sealing and signature of bridge plans is an important element of the Bridge QC/QA process.It signifies review and responsible charge of the design and details represented in the plans. The

Bridge and Structures Office intends to have at least one Licensed Structural Engineer seal and

sign each contract plan sheet (except the bar list). For major projects, the Design Unit Manager

and the Bridge Design Engineer will typically review, seal, and sign the bridge plans. For routine

bridge designs and transportation structure designs, the Design Unit Manager (SE License) and

designer with a Civil Engineer License will typically review, seal, and sign the contract plans

(except the bar list).


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B. PS&E Prepared by Consultant

This section is yet to be developed, but it will include the following elements:

Consultant Coordinator Responsibilities

Scope of WorkNegotiate Contract (Task Assignments)

Coordinate/Negotiate Changes to Scope of Work

WSDOT Design Reviewer/Coordinator Responsibilities

Review consultants design criteria and standard details early in the project

Identify resources needed to complete work

Early agreement on structural concepts/design method to be used

Identify who is responsible for what

Monitor progress

Facilitate communication

Review for design consistency with WSDOT practices and other bridge designs in project

Resolve differencesAssure that consultants QC/QA plan was followed during design

Design Unit Manager Responsibilities

Encourage/Facilitate communication

Early involvement to assure that design concepts are appropriate

Empower Design Reviewer/Coordinator

Facilitate resolution of problems beyond ability of Reviewer/Coordinator

S&E Unit Responsibilities

Prepare Specials and Estimate based on Consultants special provision checklist and quanti-

ties

Review plans for consistency

Forward Special Provisions and Estimate to consultant for review and comment

Bridge Design Engineer Responsibilities

Cursory review of design plans

Signature approval of S&E bridge contract package

C. Consultant PS&E On County and City Right of Way Projects

Consultants are frequently used by counties and cities to design bridges. The Highways and Local

Programs Office determines which projects are to be reviewed by the Bridge and Structures Office.

Where a review is required, the PS&E is sent by Highways and Local Programs to the Bridge Projects

Engineer for assignment. The Bridge and Structures Office Consultant Coordinator does not become

involved.

A Review Engineer will be assigned to the project and will review the project as outlined for

Consultant PS&E Projects on WSDOT Right of Way (see Section 1.3.1.B).

The plans with the reviewers comments should be returned to the Bridge Projects Unit where the

comments will be transferred to a second set of plans which will be returned to Highways and Local

Programs. The original set will be filed in the Bridge Projects Unit.


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Review is made of the Preliminary Plan first and the PS&E second. Comments are treated as advisory,

although major structural problems must be corrected. An engineer from the county, city, or consultant

may contact the reviewer to discuss the comments.

1.3.2 Design/Check Calculation File

A. File of Calculations

The Bridge and Structures Office maintains a file of all pertinent design/check calculations for

documentation and future reference.

B. Procedures

After an assigned project is completed and the bridge is built, the designer should turn in to the

manager a bound file containing the design/check calculations.

C. File Inclusions

The following items should be included in the file:

1. Index Sheets

Number all calculation sheets and prepare an index by subject with the corresponding sheet

numbers.

List the name of the project, SR Number, designer/checker initials, date (month, day, and year),

and supervisors initials.

2. Design Calculations

These should include design criteria, loadings, structural analysis, one set of moment and shear

diagrams and pertinent computer input and output data (reduced to 8 12 inch by 11 inch sheet

size).

3. Special Design Features

Brief narrative of major design decisions or revisions and the reasons for them.

4. Construction Problems or Revisions (As They Develop)

Not all construction problems can be anticipated during the design of the structure; therefore,

construction problems arise that require revisions. Calculations for revisions made during

construction should be included in the design/check calculation file when construction is

completed.

D. File Exclusions

The following items should not be included in the file:

1. Geometric calculations.

2. Irrelevant computer information.

3. Prints of Office Standard Sheets.

4. Irrelevant sketches.

5. Voided sheets.


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6. Preliminary design calculations and drawings unless used in the final design.

7. Test hole logs.

8. Quantity calculations.

E. Upon completion of the design work, fill out a Design Completed Checklist (Form 230-035).

(See Appendix 1.3-A3.)

1.3.3 Office Copy Review

Office Copy is the compiled contract documents (plans/specials) of all involved disciplines (Region,

service center, and Bridge Office). It is normally distributed for final review for compatibility,

completeness, and accuracy before final printing and going to Ad with the contract.

a. Note the due date to determine priority.

b. Review the comments from any previous reviews of the Region PS&E and check to see if the items

have been corrected.

c. Review all indexes for items related to traffic signals, illumination, signs, retaining walls, trafficbarrier, and other structural items.

d. Review the index and verify that no bridge plans have been omitted.

e. Review pertinent sections of the special provisions for consistency with the plans, design criteria,

and specifications.

f. Verify that Standard Plans and preapproved plans are called out where applicable.

g. Review pertinent plan sheets.

h. Verify consistency between Region plans and bridge plans; particularly geometry, drainage,

guardrail, and other pertinent items.

i. Determine if any nonstandard designs are shown or specified. If so, a structural review of them maybe necessary. Note any missing specifications, Standard Plans, etc.

j. Return plans and comments to the unit manager.

1.3.4 Addenda

Plan or specification revisions during the advertising period require an addendum. The Bridge Projects

Engineer will evaluate the need for the addendum after consultation with the OSC Bridge Construction

Engineer, Region, and the Plans Branch. The Bridge Design Engineer or the design unit manager must

initial all addenda.

For addenda to contract plans, obtain the original drawing from the Bridge Project Unit. Use shading to

mark all changes (except deletions) and place a revision note at the bottom of the sheet (Region and Plans

Branch jointly determine addendum date) and a description of the change. Return the original and an11 17 reduced copy to the Bridge Project Unit who will submit the reduced copy to the Plans Branchfor processing. See Chapter 10, Section 10.1.1I, for additional information.

For changes to specifications, submit a copy of the page with the change to the Bridge S&E Unit for

processing.


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1.3.5 Shop Plans

The following is intended to be a guide for checking shop plans.

A. Bridge Shop Plans

1. Mark one copy of each sheet with the following, near the title block, in red pencil or with a

rubber stamp:

Office Copy

Contract (number)

(Checkers initials) (Date)

2. On the Bridge Office copy, mark with red pencil any errors or corrections. Yellow shall be

used for highlighting the checked items, and ordinary lead (gray) pencil for other comments,

arithmetic, etc. (Only the red pencil marks will be copied onto the other copies to be returned

to the contractor.)

3. Items to be checked are typically as follows: Check against Contract Plans, Special Provisions,

and Standard Specifications.

a. Material specifications (ASTM specifications, hardness, alloy and temper, etc.).

b. Size of member and fasteners.

c. Length dimensions if shown on the Contract Plans.

d. Finish (surface finish, galvanizing, anodizing, painting, etc.).

e. Weld size and type and welding procedure if required.

f. Strand or rebar placement, jacking procedure, stress calculations, elongations, etc.

g. Fabrication reaming, drilling, and assembly procedures.

h. Adequacy of details.

i. Erection procedure.

The following items pertain only to post-tensioning shop plans:

j. Center of gravity of post-tensioning (P/T) strands matches contract plans.

k. Seating loss.

l. Friction losses.

m. Time-dependent losses.

n. Steel stress diagram.

o. Elongation of strands in all tendons. These will be compared with the field measurements.(See WSDOT Construction Manual.) For curved bridges where the lengths of the exterior

webs vary by more than 2 percent, separate elongations should be provided for each web.

p. Anchor plate size. If nonstandard, check bearing stress on concrete and flexural stress

in plate material. Test data must be on file to substantiate the adequacy of internal type

anchorages.


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q. Vent conduit at all high and low points in the spans.

r. Adequate room in the concrete members for the system.

s. Interference with other reinforcement. Special attention to this item if post-tensioning (P/T)

supplier proposes a different number of tendons than shown on the plans.

t. Offsets from soffit to bottom of conduits. Watch for sharp curvature of tendons near end

anchorages (see minimum radius requirements in Chapter 6 of BDM Criteria).

u. Strand positions in conduit in sag and summit tendon curves.

v. Stressing sequence.

w. Geometric details such as size of blockouts.

Note: Manufacturers details may vary slightly from contract plan requirements but must be

structurally adequate and reasonable.

4. Items Not Requiring Check:

a. Quantities in bill of materials.

b. Length dimensions not shown on Contract Plans except for spot checking.

5. Project Engineers Copy

If one copy has been marked by the Project Engineer (in green), do not use this as the office

copy. Transfer his corrections, if pertinent, to the office copy using red pencil.

6. Marking Copies

When finished, mark the office copy with one of three categories (in red pencil, lower

right corner).

a. APPD

(Approved, No Corrections required.)

b. AAN

(Approved as noted minor corrections only. Do not place written questions on an

approved as noted sheet.)

c. RFC

(Return for correction major corrections are required followed by resubmittal.)

If in doubt between AAN and RFC, check with the unit manager. An acceptable detail may

be shown in red. Mark the plans Approved-As-Noted provided that the detail is clearly noted

Suggested Correction Otherwise Revise and Resubmit.

Do not mark the other copies. This will be done in the Construction Support Unit. The reviewer

may be asked to proof the other copies after they have been marked.

Notify Project Engineer of any approved changes to the contract plans. Also notify the OSC

Bridge Construction Engineer, who may have to approve a change order and provide justification

for the change order.


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If problems are encountered which may cause a delay in the checking of the shop plans or

completion of the contract, notify the unit manager and the Construction Support Unit.

Return all shop drawings and Contract Plans to the Construction Support unit when checking is

completed. Include a list of any deviations from the Contract Plans which are allowed and a list

of any disagreements with the Project Engineers comments (regardless of how minor they may

be). If deviations from the Contract Plans are to be allowed, a Change Order may be required.

Alert the Construction Support Unit so that their transmittal letter may inform the Region and

the OSC Bridge Construction Engineer.

B. Sign Structure, Signal, and Illumination Shop Plans

In addition to those instructions described under Bridge Shop Plans, the following instructions

apply:

1. Review the shop plans to ensure that the pole sizes conform to the Contract Plans. Determine if

fabricator has supplied plans for each pole or type of pole called for in the contract.

2. The Project Engineers copy may show shaft lengths where not shown on Contract Plans orwhether a change from Contract Plans is required. Manufacturers details may vary slightly

from contract plan requirements, but must be structurally adequate to be acceptable.

1.3.6 Contract Plan Changes (Change Orders and As-Builts)

A. Request for Changes

The following is intended as a guide for processing changes to the design plans after a project has

been awarded.

For projects which have been assigned a Bridge Technical Advisor, structural design change orders

can be approved at the Regional level provided the instructions outlined in the Construction Manual

are followed.

For all other projects, all changes are to be channeled through the Construction Support Unit whichwill coordinate with the OSC Bridge Construction Engineer. Responses to inquiries should be

handled as follows:

1. Request by Contractor or Supplier

A designer, BTA, or design unit manager contacted directly by a contractor/supplier may discuss

a proposed change with the contractor/supplier, but shall clearly tell the contractor/supplier to

formally submit the proposed change though the Project Engineer and that the discussion in no

way implies approval of the proposed change. Designers are to inform their manager if they are

contacted.

2. Request From the Project Engineer

Requests for changes directly from the Project Engineer to the design unit manager should be

discouraged but may be acceptable when the Bridge Construction Engineer is not available. The

Bridge Construction Engineer and Construction Support Unit should be informed of any changes.

3. Request From the Region Construction Engineer

Requests from the Region Construction Engineer are to be handled like requests from the Region

Project Engineer.


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1.3-16 July 2000

4. Request From the OSC Bridge Construction Engineer

Requests for changes from the OSC Bridge Construction Engineer or his/her assistants are

usually made through the Construction Support Unit and not directly to the Design Unit.

However, sometimes, it is necessary to work directly with the Design Unit. The Construction

Support Unit should be informed of any decisions made involving changes to the Contract Plans.

5. Request From the Design Unit

Request for changes from the Design Unit due to plan error, omissions, etc., shall be discussed

with the Bridge Design Engineer prior to revising and issuing new plan sheets.

B. Processing Contract Revisions

Changes to the Contract Plans or Specifications subsequent to the award of the contract may require

a contract revision. To clearly identify the scope of work, it is often desirable to provide revised or

additional drawings. When a revision or an additional drawing is necessary, request the original

mylars from the Construction Support Units Plans Technician and prepare revised or new original

mylars.Send the new mylars to the Construction Support Units Plans Technician. The OSC Construction

Office requires two reduced paper copies; Construction Support Unit requires one reduced paper

copy; Design Unit requires one or more reduced paper copies; one full-sized paper print, stamped

As Constructed Plans, shall be sent to the Project Engineer who shall use it to mark construction

changes and upon project completion, forward them to the Construction Support Bridge Plans

Technician. The Designer is responsible for making the prints and distributing them.

This process applies to all contracts including OSC Ad and Award, Region Ad and Award, or Local

Agency Ad and Award.

Whenever new plan sheets are required as part of a contract revision, the information in the title

blocks of these sheets must be identical to the title blocks of the contract they are for (e.g., Job

Number, Contract No., Fed. Aid Proj. No., Approved by, and the Project Name). These title blocksshall also be initialed by the Bridge Design Engineer, manager, designer, and reviewer of the change

before they are distributed. If the changes are modifications made to an existing sheet, the sheet

number will remain the same. A new sheet shall be assigned the same number as the one in the

originals that it most closely applies to and shall also be given a letter (e.g., the new sheet applies to

the original sheet 25 of 53 so it will be number 25A of 53). A full size mylar of the contract revision

sheet shall be stored in the Bridge Projects Unit.

Every revision will be assigned a number which shall be enclosed inside a triangle (e.g., 1 ).

The assigned number shall be located both at the location of the change on the sheet and in the

revision block of the plan sheet along with an explanation of the change.

Any revised sheets shall be sent to the OSC Construction Office with a written explanation describing

the changes to the contract, justification for the changes, and a list of material quantity additions

or subtractions.


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1.3.7 Archiving Design Calculations, Design Files, and S&E Files

Upon Award, the following information will be collected by the Bridge Standard Plans Engineer.

Design File

S&E File

Design Calculations

Place a job file cover sticker on the file folder (see Figure 1). Fill in all fields completely. Keep these files

on site for future reference until the end of the retention period. Update the file with any contract plan

changes that occur during construction. After the retention period, send the files to the Office of the

Secretary of State for archiving at:

Archives & Records Management

1129 Washington Street SE

Olympia, WA 98504-0238

Telephone: 360-586-4900

SR # _____ County ____________________ CS # _____

Bridge Name _____________________________________

Bridge # _______________ Contract # ________________

Contents ________________________________________

Designed by _____________ Checked by _____________

Archive Box # _____________________ Vol. # _______

Figure 1

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General Information Coordination With Other Divisions and Agencies

1.4 Coordination With Other Divisions and Agencies

During the various phases of design, it is necessary to coordinate the elements of the bridge design

function with the requirements of other divisions and agencies. E-mail messages, telephone calls, and

other direct communication with other offices are necessary and appropriate. Adequate communications

are essential but organizational format and lines of responsibility must be recognized. However, a written

request sent through channels is required before work can be done or design changes made on projects.

1.4.1 Preliminary Planning Phase

See Chapter 2.1 of this manual for coordination required at preliminary planning phase.

1.4.2 Final Design Phase

A. Coordination With Region

During this phase, final coordination of the bridge design with region requirements must be

accomplished. This is normally done with the Region Project Engineer, Region Design Engineer,

or Region Plans Engineer. Details such as division of quantity items between the region PS&E and

bridge PS&E become highly important to a finished contract plan set. The region PS&E and bridgePS&E are combined by the Region Plans Branch. However, necessary coordination should be

accomplished before this time.

During the design of a project for a region level contract, the region shall provide a copy of the

proposed structural plans (such as retaining walls, barrier, large culverts, etc.) to the Bridge and

Structures Office. Bridge and Structures Office will review these plans and indicate any required

changes, then send them back to the region.

The region shall incorporate the changes prior to contract advertisement.

After contract advertisement, the region shall return the original plan sheets to Bridge and Structures

Office. These sheets shall be held in temporary storage until the As Constructed Plans for them are

completed by the region.The region shall then transmit the As Constructed Plans to Bridge and Structures Office where

they will be transferred to the original plans for permanent storage. Upon request, the region will be

provided copies of these plans by Bridge and Structures Office.

B. Technical Design Matters

Technical coordination must be done with the OSC Materials Laboratory Foundation Engineer and

with the OSC Hydraulic Engineer for matters pertaining to their responsibilities. A portion of the

criteria for a project design may be derived from this coordination, otherwise it shall be developed

by the designer subject to approval of the Bridge Design Engineer.

When two or more structures are to be let under the same contract, the designer should make a special

effort to be uniform on structural details, bid items, specifications, and other items.

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General Information Bridge Design Scheduling

1.5 Bridge Design Scheduling

1.5.1 General

The Bridge Projects Engineer is responsible for scheduling and monitoring the progress of projects.

The Bridge Design Schedule is used to track the progress of a project and is updated monthly. A typicalproject would involve the following steps:

A. Regions advise Bridge and Structures Office of an upcoming project.

B. The Bridge Projects Unit estimates design time required for preliminary plans, design, and S&E

(see Section 1.5.2).

C. The project is entered into the Bridge Design Schedule with start and due dates for site data

preliminary plan, project design, PS&E, and the ad date.

D. Bridge site data received.

E. Preliminary design started.

F. Final Design Started Designer estimates time required for final plans (see Section 1.5.3).

G. Monthly Schedule Update Each Design Unit Supervisor turns in to the Bridge Scheduling

Engineer an updated copy of the Bridge Design Schedule showing man-months used last month,

man-months used to date, percentage complete, and adjustments required in the schedule. The report

is due by the fourth working day of the month.

H. Project turned in to S&E unit.

1.5.2 Preliminary Design Schedule

The preliminary design estimate done by the Bridge Projects Unit is based on historical records from

past projects factoring in unique features of each individual project, the efficiencies of designing similar

bridges on the same project, CADD system efficiencies, designer experience, and other factors as

appropriate.

1.5.3 Final Design Schedule

A. Breakdown of Project Man-Hours Required

Using a spreadsheet, list each item of work required to complete the project and the man-hours

required to accomplish them. Certain items of work may have been partially completed during the

preliminary design, and this partial completion should be reflected in the columns % Completed

and Date Completed. Formerly, WSDOT Form 232-002 (see Appendix 1.5-A1), was used to

monitor project progress. This form can still be used.

The designer or team leader should research several sources when making the final design time

estimate. The following are possible sources that may be used:

The Bridge Design Summary contains records of design time and costs for past projects. The

summary is kept in the Bridge Projects Unit. The times given include preliminary plan, design,

check, drafting, and supervision as reported on the summary from the Accounting Office.

The Bridge Projects Unit has Bridge Construction Cost Summary books. These are grouped

according to bridge types and have records of design time, number of drawings, and bridge cost.

The hours shown are the total for the bridge as reported from the designers time sheets.

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B. Estimate Design Time Required

The designer or design team leader shall determine an estimate of design time required to complete

the project. The use of a spreadsheet, Microsoft Project, or other means is encouraged to ensure

timely completion and adherence to the schedule. In the past, WSDOT Form 232-003 was used.

Typically, the following completion percentages (percent of the total project time) from Form

232-002 are applied on Form 232-003 for the following activities:

Activity No. Percentage

1 40

2 20

3 25

4 5

5 5

7 5

Completion percentages for Activities 4, 5, and 7 are approximately 5 percent of the project total.

Activity 6 is separate from design time required by needs to be included to determine the

completion date.

Activities 8 and 9 are estimates dependant on individual circumstances.

Note: Activities 1 through 5 and Activity 7 make up 100 percent of the design time required to

complete the job.

The individual activities include the specific items as follows under each major activity.

Activity No. 1 Design Includes:

1. Project coordination.

2. Geometric computations.3. Design calculations (including time for Load Rating).

4. Complete check of all plan sheets by the designer.

5. Supervisor time related to design (estimate 10 percent of design time).

Activity No. 2 Design Check As defined in Section 1.3.1A3 Includes:

1. Checking design at maximum stress locations.

2. Checking major items on the drawings, including geometrics.

3. Additional checking required.

4. Supervisor time related to checking (estimate 10 percent of design

check time).

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Activity No. 3 Drawings Includes:

Preparation of all drawings.

Activity No. 4 Revisions Includes:

1. Revisions resulting from the checkers check.

2. Revisions resulting from the supervisory review.

Activity No. 5 Quantities Includes:

1. Compute quantities including bar list.

2. Check quantities.

Activity No. 6 S&E Includes:

1. Preparing special provisions checklist.

2. Assemble backup data covering any unusual feature.

Activity No. 7 Review Includes:

1. Supervisors review.

Activity No. 8 Other Jobs Includes:

1. Interruptions.

Activity No. 9 Leave Includes:

1. Annual, sick, and other leave.

See Figures 1.5.2-1 and 2 for sample Bar Chart problem and corresponding progress report form.

C. Monthly Project Progress Report

The designer or design team leader is responsible for determining monthly project progress and

reporting the results to the Unit Supervisor. In the past, WSDOT Form 232-004 (see Appendix

1.5-A2) was used to monitor the progress of the project design. The Design Unit Supervisor is

required to update a copy of the bridge design schedule each month using information from the

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