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New York State Thruway Authority
Thruway Structures Design Manual - 3rd Edition

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PDF Outside Cover (PDF, 1 pages/132 Kb)

PDF Inside Cover (PDF, 3 pages/122 Kb)

PDF Endorsement Letter (PDF, 1 page/35.3 Kb)

To order a hard copy of the Thruway Structures Design Manual send a check for $50.00 to the New York State Thruway Authority, Attention: Contracts Unit, 200 Southern Blvd, Albany, NY 12209.

Table of Contents

Section 1
Section Title Page
1 PDF GENERAL (PDF, 37 pages/1.03 Mb) 1-1
1.0 Capital Project Process 1-1
1.1 Aesthetics 1-3
1.2 Abutment Plantings 1-8
1.3 Hydrology & Hydraulics
1.3.1   Hydraulic Analysis and Design Reports
1.3.2   Freeboard
1.3.3   Other Design Considerations
1.3.4   Hydraulic and Scour Assessment Reports		 1-12
1-12
1-13
1-14
1-14
1.4 Bridge Fencing and Right-Of-Way Fencing
1.4.1   Snow Fencing
1.4.2   Protective Screening
1.4.3   Right-Of-Way Fencing 		1-15
1-16
1-16
1-17
1.5 Municipality Coordination and Communication
1.5.1   Project Initiation Letter - (Municipality Coordination)
1.5.2   Chapter 766 of the Laws of 1992
1.5.3   Maintenance and Repair Agreements 		1-18
1-18
1-19
1-20
1.6 Utility Coordination and Communication
1.6.1   Project Initiation Letter - (Utilities)
1.6.2   Occupancy Permits
1.6.3   Thruway Policy on Utility Relocation 		1-21
1-22
1-22
1-23
1.7 Horizontal Roadside Clearances
1.7.1   Clear Zone Requirements
1.7.2   Roadside Hazards 		1-27
1-27
1-30
1.8 Minimum Bridge Vertical Underclearance for Overhead Structures on the Thruway System
1.8.1   Vehicle Structures over the Thruway Mainline and Ramps
1.8.2   Pedestrian and Sign Structures Over the Thruway Mainline and Ramps
1.8.3   Thruway Mainline and Ramp Structures		 1-31

1-33
1-33

1-34
1.9 Minimum Clearances at Railroad Tracks
1.9.1   Vertical Underclearances
1.9.2   Horizontal Clearances
1.9.3   Crash Walls 		1-34
1-35
1-35
1-36

Section 2
Section Title Page
2 PDF LOADS & RATINGS (PDF, 7 pages/96.2 Kb) 2-1
2.1 Design Loads on Structures
2.1.1   Design Live Loads
2.1.2   Design Dead Loads
2.1.3   Design and Future Superimposed Dead Loads
2.1.4   Design Load Table
2.1.5   Moment and Shear Tables on Contract Plans 		2-1
2-1
2-1
2-2
2-3
2-4
2.2 Load Rating of Structures 2-6

Section 3
Section Title Page
3 PDF DECK SYSTEMS (PDF, 68 pages/5.17 Mb) 3-1
3.0 Thruway Deck Slab and Overlay Policy
3.0.1   New and Replacement Thruway Mainline
and Ramp Bridges
3.0.2   Rehabilitated Thruway Mainline and Ramp Bridges
3.0.3   New and Replacement Overhead Bridges
3.0.4   Rehabilitated Overhead Bridges
3.0.5   Future Wearing Surface 		3-1
3-1

3-1
3-1
3-2
3-2
3.1 Cast-In-Place Concrete Deck Slabs
3.1.1   Monolithic Decks
3.1.2   Two-Course Decks
3.1.3   Reinforcement in Bridge Decks
3.1.4   Reinforcement in Overhang Regions
3.1.5   Haunches
3.1.6   Forming
3.1.7   Concrete Placement 		3-3
3-3
3-7
3-12
3-19
3-29
3-30
3-30
3.2 Prefabricated Deck Systems
3.2.1   Exodermic™ Bridge Deck
3.2.2   INVERSET™ Bridge System 		3-39
3-39
3-53
3.3 Concrete Sealants Applied to Structural Decks
3.3.1   Driving and Sidewalk Surfaces
3.3.2   Fascia Surfaces 		3-59
3-59
3-59
3.4 Stage Construction
3.4.1   Guidelines for Stage Construction of Deck Slabs on Steel Stringers
3.4.2   Guidelines for Stage Construction of Deck Slabs on Prestressed Concrete Beams		 3-60

3-60

3-64
3.5 Shoulder Treatment 3-66
3.6 Bridge Deck Drainage 3-67

Section 4
Section Title Page
4 PDF SUBSTRUCTURES (PDF, 112 pages/6.02 Mb) 4-1
4.1 Foundations
4.1.1   Footings in Rock
4.1.2   Stepped Footings
4.1.3   Design Footing Pressures and Pile Capacities
4.1.4   Piles 		4-1
4-2
4-4
4-5
4-7
4.2 Excavation and Backfill
4.2.1   Excavation and Backfill at Structures
4.2.2   Drainage of Backfill
4.2.3   Sheeting and Cofferdams
4.2.4   Tremie Seal 		4-10
4-11
4-11
4-14
4-14
4.3 Embankment and Slope Protection
4.3.1   Slope Protection
4.3.2   Berms 		4-14
4-15
4-19
4.4 Substructure Materials
4.4.1   Structural Concrete Item for Substructure Concrete
4.4.2   Galvanized Reinforcement in Substructures 		4-21
4-21
4-21
4.5 Abutment Features
4.5.1   General
4.5.2   Abutment Stems
4.5.3   Cantilevered Wingwalls (In-Line and Flared)
4.5.4   Free-Standing Wingwalls (In-Line and Flared)
4.5.5   Battered and Stepped Wingwalls
4.5.6   U-Wall Wingwalls
4.5.7   Curved Wingwalls
4.5.8   Other Wingwall Types 		4 21
4 21
4-22
4-23
4-24
4-26
4-26
4-27
4-27
4.6 Integral Abutments
4.6.1   Guidelines on Use
4.6.2   Design and Detail Considerations
4.6.3   Integral Abutment Bridge Design Procedures 		4-28
4-29
4-31
4-49
4.7 Jointless Bridge Abutments
4.7.1   Guidelines on Use
4.7.2   Design and Detail Considerations 4-58
4.7.3   Jointless Bridge Abutment Bridge Design Procedures 4-66		 4-53
4-56
4-58
4-66
4.8 Semi-Integral Abutments with Curtain Wall Backwalls
4.8.1   Guidelines on Use
4.8.2   Design and Detail Considerations
4.8.3   Semi-Integral Abutment Bridge Design Procedures 		4-69
4-70
4-73
4-81
4.9 Conventional Stem Abutments with Bridge Expansion Joints
4.9.1 Guidelines on Use
4.9.2 Design and Detail Considerations
4.9.3 Conventional Abutment Bridge Design Procedures 		4-84
4-84
4-89
4-96
4.10 Piers
4.10.1   New Piers
4.10.2   Existing Piers		 4-98
4-98
4-107
4.11 Concrete Sealants
4.11.1   Solid Color Protective Concrete Sealer
4.11.2   Clear Penetrating Sealer		 4-108
4-108
4-109
4.12 Concrete Joints
4.12.1   Types of Joints
4.12.2   Application of Joints 		4-109
4-109
4-110

Section 5
Section Title Page
5 PDF REINFORCEMENT (PDF, 30 pages/1.22 Mb) 5-1
5.1 Galvanized Reinforcement 5-1
5.2 Reinforcement Grade 5-2
5.3 Spacing 5-2
5.4 Cover 5-3
5.5 Maximum Bar Lengths 5-5
5.6 Splicing Reinforcement
5.6.1   General
5.6.2   Splicing Reinforcement in Decks
5.6.3   Splicing Reinforcement in Wall Stems
5.6.4   Splicing Reinforcement in Pier Stems and Columns 		5-5
5-5
5-7
5-9
5-10
5.7 Marking of Bars 5-11
5.8 Bar Bending Diagrams & Standard Hooks 5-12
5.9 Drilling and Grouting Reinforcing Bars
5-13
5.10 Minimum Reinforcement Requirements
5.10.1   Footings - Abutments and Piers
5.10.2   Walls, Stems and Solid Piers
5.10.3   Columns
5.10.4   Stirrups and Ties		 5-16
5-16
5-17
5-18
5-19
5.11 Reinforcement Development Lengths and Lap Lengths 5-19
5.12 Suggested Reinforcement Placement Details
5.12.1   Design Reinforcement - Spread Footings
5.12.2   Dowel Placement – Footing into Stem
5.12.3   Possible Dowel Combinations
5.12.4   Compression Bars		 5-24
5-24
5-26
5-26
5-29

Section 6
Section Title Page
6 PDF PRESTRESSED CONCRETE (PDF, 11 pages/662 Kb) 6-1
6.1 Design 6-1
6.2 Width - Box Beams and Slab Beams 6-2
6.3 Camber 6-3
6.4 Diaphragms
6.4.1   Box and Slab Beams
6.4.2   I-Beams 		6-3
6-3
6-4
6.5 Transverse Tendons for Box and Slab Beams 6-4
6.6 Concrete Slab for Box and Slab Beams 6-8
6.7 Shear Keys 6-9
6.8 Miscellaneous 6-11

Section 7
Section Title Page
7 PDF STRUCTURAL STEEL (PDF, 31 pages/1.30 Mb) 7-1
7.1 Structural Steel Types
7.1.1   Combinations of Different Types of Structural Steel 		7-1
7-1
7.2 Minimum Thickness of Metal 7-2
7.3 Camber
7.3.1   Sag Cambers		 7-3
7-3
7.4 Bottom of Slab Elevations 7-4
7.5 Flange Thickness and Width Changes 7-5
7.6 Designation of Tension Zones 7-5
7.7 Intermediate Stiffeners and Connection Plates
7.7.1   General
7.7.2   Simple Spans
7.7.3   Continuous Spans 		7-7
7-7
7-7
7-9
7.8 Longitudinal Stiffeners 7-9
7.9 Bearing Stiffeners
7-9
7.10 Diaphragms & Cross Frames
7.10.1   Diaphragms
7.10.2   Cross Frames 		7-10
7-11
7-14
7.11 Lateral Bracing 7-17
7.12 Cover Plates 7-17
7.13 Safety Handrails 7-18
7.14 Drip Bars
7.14.1   Drip Bar Fasteners
7.14.2   Drip Bar Sealing		 7-18
7-18
7-18
7.15 Widths of Outstanding Legs of Angles 7-19
7.16 Copes for Framed Connections 7-19
7.17 Minimum Size of Fillet Welds 7-20
7.18 Fasteners
7.18.1   Size of Fasteners (High Strength Bolts)
7.18.2   Spacing of Fasteners
7.18.3   Maximum Spacing of Fasteners
7.18.4   Edge Distance of Fasteners 		7-20
7-20
7-21
7-22
7-22
7.19 Field Splices
7.19.1   Welded Field Splices
7.19.2   Bolted Field Splices 		7-23
7-23
7-23
7.20 Bearings Welded to Beams or Girders 7-24
7.21 Shear Connectors
7.21.1   Shear Connector Length
7.21.2   Minimum Cover
7.21.3   Shear Connector Diameter
7.21.4   Shear Connector Placement
7.21.5   Design Methods
7.21.6   Sizing Limitation
7.21.7   Shear Connector Spacing and Edge Distance 		7-25
7-25
7-28
7-28
7-28
7-29
7-29
7-29
7.22 Unpainted Weathering Steel
7.22.1   Exclusions to Use of Weathering Steel
7.22.2   Use of Weathering Steel
7.22.3   Fasteners for Weathering Steel
7.22.4   Drip Bar Fasteners - Weathering Steel Application
7.22.5   Additional Steel Thickness
7.22.6   Structural Steel Painting at Expansion Joints
7.22.7   Special Notes 		7-30
7-30
7-30
7-31
7-31
7-31
7-31
7-31

Section 8
Section Title Page
8 PDF BEARING DEVICES (PDF, 51 pages/4.29 Mb) 8-1
8.1 General
8.1.1   Bearing Use Criteria
8.1.2   Bearing Pads
8.1.3   Beveling of Plates
8.1.4   Anchor Bolt Design
8.1.5   Anchor Bolt Hole Edge and End Distance 		8-1
8-1
8-1
8-3
8-3
8-8
8.2 Cement Mortar Pads and Plain Elastomeric Pads
8.2.1   Cement Mortar Pads
8.2.2   Plain Elastomeric Pads 		8-9
8-9
8-11
8.3 Preformed Fabric Bearings
8.3.1   Preformed Fabric Non-Guided Expansion Bearings
8.3.2   Preformed Fabric Fixed Bearings 		8-13
8-13
8-15
8.4 Multi-Rotational (Pot-Type) Bearings
8.4.1   Guided Expansion Pot Bearings
8.4.2   Fixed Pot Bearings 		8-16
8-16
8-19
8.5 Multi-Rotational (Disc-Type) Bearings
8.5.1   Guided Expansion Disc Bearings
8.5.2   Fixed Disc Bearings 		8-21
8-22
8-24
8.6 Spherical Bearings (Multi-Rotational)
8.6.1   Spherical Guided Expansion Bearings
8.6.2   Spherical Fixed Bearings		 8-27
8-27
8-32
8.7 Elastomeric Bearings
8.7.1   Elastomeric Expansion Bearings
8.7.2   Elastomeric Fixed Bearings 		8-35
8-35
8-41
8.8 Seismic Isolation Bearings
8-43

Section 9
Section Title Page
9 PDF JOINTS (PDF, 30 pages/3.03 Mb) 9-1
9.1 Joint Types 9-1
9.2 Joint Selection Criteria
9.2.1   Cold Poured Joints
9.2.2   Hot Poured Joints
9.2.3   Inflated Neoprene Seal
9.2.4   Preformed Silicone Joint
9.2.5   Strip Seals
9.2.6   Armored Joints
9.2.7   Vermont Joints (Open & Finger)
9.2.8   Modular Joints 		9-1
9-3
9-6
9-8
9-11
9-14
9-17
9-17
9-22
9.3 Rail, Barrier, Curbs and Sidewalks
9.3.1   Steel Bridge Rail with Curbs or Sidewalks
9.3.2   Concrete Median or Fascia Barrier
9-25
9-25
9-28
9.4 Snow Plow Angle 9-30

APPENDIX
Appendix Title Page
A PDF EXAMPLE TITLE SHEETS AND TABLES (PDF, 7 pages/1.50 Mb)

EXAMPLE 1. - TITLE SHEET (In-House Design)
EXAMPLE 2. - TITLE SHEET (Consultant Design)
EXAMPLE 3. - ESTIMATE of QUANTITIES
EXAMPLE 4. - MOMENT AND SHEAR TABLES
EXAMPLE 5. - HAUNCH TABLE (New Construction)
EXAMPLE 6. - HAUNCH TABLE (Rehab. Deck Replacement Only) 		A-1

A-2
A-3
A-4
A-5
A-6
A-7
B PDF NOTES (PDF, 50 pages/1.45 Mb)

A. Index
B. Notes to be Placed on the General Note Sheet
C. Notes to be Placed in the Body of the Plans 		B-1

B-3
B-GN1-1
B-BP1-1
C

PDF STANDARD DETAILS - INDEX (PDF, 4 pages/78.3 Kb)

PDF C1. PILES (PDF, 5 pages/630 Kb)

PDF C2. WATERSTOP (PDF, 11 pages/1.39 Mb)

PDF C3. SUBSTRUCTURE (PDF, 26 pages/4.19 Mb)

PDF C4. MASONRY (PDF, 3 pages/558 Kb)

PDF C5. STEEL (PDF, 7 pages/654 Kb)

PDF C6. SLAB (PDF, 8 pages/0.98 Mb)

PDF C7. SCUPPER (PDF, 7 pages/1.02 Mb)

PDF C8. CONCRETE BARRIER (PDF, 6 pages/685 Kb)

PDF C9. CURB (PDF, 5 pages/469 Kb)

PDF C10. DRAINAGE (PDF, 5 pages/469 Kb)

PDF C11. RAILING (PDF, 6 pages/1.17 Mb)

PDF C12. ANCHOR BOLTS (PDF, 2 pages/274 Kb)

PDF C13. BEARINGS (PDF, 3 pages/363 Kb)

PDF C14. PRESTRESSED CONCRETE (PDF, 4 pages/546 Kb)

C-1
D PDF GLOSSARY (PDF, 13 pages/123 Kb) D-1
E PDF CHECKLISTS (PDF, 1 page/57.7 Kb) E-1
F PDF GUIDELINES FOR WELDING STRUCTURAL STEEL FOR
BRIDGES (PDF, 17 pages/145 Kb) 		F-1

Additional Resources

PDF 2002 NYSDOT Engineering Bulletins (PDF, 6 pages/64.8 Kb)

PDF 2002 NYSDOT Engineering Instructions (PDF, 3 pages/66.4 Kb)

PDF 2003 NYSDOT Engineering Bulletins (PDF, 5 pages/68.3 Kb)

PDF 2003 NYSDOT Engineering Instructions (PDF, 3 pages/63.7 Kb)

PDF 2004 NYSDOT Engineering Bulletins (PDF, 4 pages/59.2 Kb)

PDF 2004 NYSDOT Engineering Instructions (PDF, 3 pages/73.9 Kb)

PDF 2005 NYSDOT Engineering Bulletins (PDF, 2 pages/51.0 Kb)

PDF 2005 NYSDOT Engineering Instructions (PDF, 1 page/56.4 Kb)

PDF AASHTO Article 10.29.6 – Anchor Bolts (PDF, 1 page/83.5 Kb)

PDF AASHTO Article 14.7.3 – Anchorage (PDF, 1 page/66.7 Kb)

PDF Thruway Standard Sheet Deck Repairs (PDF, 1 page/326 Kb)

PDF Thruway Standard Sheet Concrete Repairs (PDF, 1 page/300 Kb)

PDF Example of a Thruway CP3 (PDF, 2 pages/183 Kb)

PDF Thruway Design Bulletin DB00-03–Safety Appurtenance Upgrades (PDF, 6 pages/376 Kb)

PDF Thruway Design Bulletin DB97-02 – Roadside Design (PDF, 6 pages/404 Kb)

PDF Example of Thruway Design Recommendation (PDF, 4 pages/149 Kb)

PDF Example of Thruway Design Report (PDF, 21 pages/171 Kb)

PDF Municipality Coordination Checklist (PDF, 1 page/57.7 Kb)

PDF Item 25632.0301M – Precast Concrete Wall (PDF, 5 pages/90.7 Kb)

PDF Guide to Prefabricated Retaining Wall Systems (PDF, 37 pages/1.14 Mb)

PDF Project Development Guide (PDF, 4 pages/125 Kb)

PDF Rational Design of Integral Abutment Piles (PDF, 12 pages/762 Kb)

PDF Typical Prefabricated Wall Details (PDF, 1 page/360 Kb)

PDF Example of Thruway Scope Summary/Design Recommendation (PDF, 5 pages/99.2 Kb)

PDF AASHTO Article 3.24.3.2 – Case B-Main Reinforcement Parallel to Traffic (PDF, 1 page/58.4 Kb)

PDF Utility Coordination Checklist (PDF, 1 page/56.4 Kb)

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