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4. DECK INSTALLATION

The figures in this section illustrate the steps in a typical deck installation. Where available, actual dates are noted for each step to provide a timeline for the operation.

Figure 12. Photo. Stringline girders to determine if haunch corrections are needed. Note that the A588 stringer has replaced one that was corroded due to the previous open grating.
Figure 12. Photo. Stringline girders to determine if haunch corrections are needed. Note that the A588 stringer has replaced one that was corroded due to the previous open grating.

Figure 13. Photo. Place prefabricated haunches (black epoxy-coated red oak).
Figure 13. Photo. Place prefabricated haunches (black epoxy-coated red oak).

Figure 14. Photo. Situate crane and pick panels with two slings. Approximate panel weight is 20 psf, including wearing surface course 1. On this project, a panel weighed approximately 1,800 lb.
Figure 14. Photo. Situate crane and pick panels with two slings. Approximate panel weight is 20 psf, including wearing surface course 1. On this project, a panel weighed approximately 1,800 lb.

Figure 15. Photo. Place panels on top of prefabricated haunches. Note studs that make a fixed connection between the deck and stringers at midspan.
Figure 15. Photo. Place panels on top of prefabricated haunches. Note studs that make a fixed connection between the deck and stringers at midspan.

Figure 16. Photo. Place prefabricated deck panels so transverse field joints are as tight as possible, making fine adjustments with a steel road bar.
Figure 16. Photo. Place prefabricated deck panels so transverse field joints are as tight as possible, making fine adjustments with a steel road bar.

Figure 17. Photo. Secure panels with stainless steel clips and expansion bolts. Expansion bolt is shown.
Figure 17. Photo. Secure panels with stainless steel clips and expansion bolts. Expansion bolt is shown.

Figure 18. Photo. Secure panels with stainless steel clips and expansion bolts. Clip is shown.
Figure 18. Photo. Secure panels with stainless steel clips and expansion bolts. Clip is shown.

Figure 19. Photo. Installed clip. Methacrylate adhesive can be used to fill voids above or below prefabricated haunches to ensure uniform bearing. This was done on 9/4/2012.
Figure 19. Photo. Installed clip. Methacrylate adhesive can be used to fill voids above or below prefabricated haunches to ensure uniform bearing. This was done on 9/4/2012.

Figure 20. Photo. Install fixed connection between deck and steel stringers per plan.
Figure 20. Photo. Install fixed connection between deck and steel stringers per plan.

Figure 21. Photo. Install 5/8-inch foam backer rod at bottom of field joints.
Figure 21. Photo. Install 5/8-inch foam backer rod at bottom of field joints.

Figure 22. Photo. Install transverse rebar and epoxy grout in field joints. Thirty-six-inch #3 stainless rebar provides a positive tie across the centerline joint.
Figure 22. Photo. Install transverse rebar and epoxy grout in field joints. Thirty-six-inch #3 stainless rebar provides a positive tie across the centerline joint.

Figure 23. Photo. Embed clean, dry, angular aggregate on the surface of the epoxy-grout field joints.
Figure 23. Photo. Embed clean, dry, angular aggregate on the surface of the epoxy-grout field joints.

Figure 24. Photo. Mix epoxy grout for deck nosing at bridge joints.
Figure 24. Photo. Mix epoxy grout for deck nosing at bridge joints.

Figure 25. Photo. Install 1-inch foam backer board at bridge joint at each end of the deck to square up the end of the deck. Install epoxy grout in deck nosing at joints.
Figure 25. Photo. Install 1-inch foam backer board at bridge joint at each end of the deck to square up the end of the deck. Install epoxy grout in deck nosing at joints.

Figure 26. Photo. Apply resin for second course of wearing surface.
Figure 26. Photo. Apply resin for second course of wearing surface.

Figure 27. Photo. Broadcast crushed stone for second course of wearing surface.
Figure 27. Photo. Broadcast crushed stone for second course of wearing surface.

Figure 28. Photo. Spread crushed stone aggregate for second course of wearing surface. Then install 1-inch foam backer rod at the bottom of the begin and end bridge joints (not pictured).
Figure 28. Photo. Spread crushed stone aggregate for second course of wearing surface. Then install 1-inch foam backer rod at the bottom of the begin and end bridge joints (not pictured).

Figure 29. Photo. Install two-part pourable joint material per manufacturer’s instructions.
Figure 29. Photo. Install two-part pourable joint material per manufacturer's instructions.

igure 30. Photo. Align prefabricated high-density polyethylene pad for bridge railing posts.
Figure 30. Photo. Align prefabricated high-density polyethylene pad for bridge railing posts.

Figure 31. Photo. Install bridge railing posts, rails, and approach railing.
Figure 31. Photo. Install bridge railing posts, rails, and approach railing. Opened to traffic on 9/27/2012.

Figure 32. Photo. Load test to determine the load capacity of the bridge; not normally needed to assess the deck.
Figure 32. Photo. Load test to determine the load capacity of the bridge; not normally needed to assess the deck.

A sample specification for this deck system is provided in appendix D. Appendix E is a set of engineering drawings used to illustrate the deck and installation details.

 

Page last modified on May 18, 2012.
Federal Highway Administration | 1200 New Jersey Avenue, SE | Washington, DC 20590 | 202-366-4000