Rev : Mac 2012

1.1 TERMS OF REFERENCE FOR BRIDGES AND VIADUCTS

STRUCTURES (CONVENTIONAL)

1.2 Geometric Standards

The bridge geometric standards shall conform to JKR U5/R5 Arahan Teknik Jalan 8/86.

1.3 Materials

The bridge and viaduct structures shall be of steel or concrete construction. The
Consulting Engineer (CE) shall use local materials, particularly locally produced steel,
unless otherwise approved by the Superintending Officer (S.O.).
Materials shall be durable and adequate protection shall be provided against
environmental deterioration. Minimum grade of concrete allowable is Grade 40. Where the
bridge is exposed to chlorides, high performance concrete shall be used.
1.4 Design Consideration
(a) All structural design must be on the Industrial Building System (IBS) as
follows:
i) Minimum percentage IBS content calculated based on cost of structural
works fixed at 70%;
ii) Foundation works are not taken into account in the
calculation;
iii) Other simplified construction solution for cast in-situ concrete
superstructure, the maximum score for reusable system formwork allowed
is only 50% such as:
a) balanced cantilever construction
b) movable scaffolding system (MSS)
c) other similar labour saving systems

iv) All reinforced for cast in-situ structure shall be cut and bent off site
complying to MS146 as well as BS 4466 and BS 5400;
v) The CE must submit calculation for percentage of IBS content when
submitting structural drawing for verification.
(b) Appropriate investigations and data collection shall be carried out to determine the
best design. The investigation shall include at least the followings:
(i) Investigation and evaluation of the most appropriate structural forms and
span configurations that optimally satisfy the requirements of visual
elegance, functional adequacy, safety, robustness, suitability, ease of
maintenance and cost effectiveness.

(ii) Hydraulic and hydrology data: as required to determine the soffit levels
and deck finished levels of the bridges, river training, scour depth
estimation, etc.

1
 (iii) Weather and climatic data: required in drainage design and bridge
loadings. Where it is envisaged that wind loadings may have a significant
effect on the stability and serviceability of the structure, appropriate wind
tunnel testing shall be carried out.

(iv) Investigation of the most appropriate seismic loadings for the bridge
structure in order to incorporate adequate protection against such
occurrences.
(v) Navigational requirements for navigable bridge: as required to determine
soffit levels, minimum navigational spans, protection against ship impact,
navigational lighting, etc.
(c) Bridges of total length not exceeding 60.0 meters with skews not exceeding 30°
shall be designed as integral bridges.
(d) The superstructure of bridge and viaducts shall be structurally continuous with the
minimum of expansion joints. Where point of fixity of piers and piling systems are
more than 10.0 m or where possible, the superstructure and piers shall have an
integral crossheads designed to developed full continuity moments.
Continuity connection using tied deck slab is not allowed. Abutment details shall
be semi-integral whenever possible.
(e) Beam of less than 30.0 m shall be of the new JKR standard Beam Sections.
(f) Cantilever beams of T-shaped piers carrying 6-lane dual carriageway or wider
shall be fully prestressed.
(g) Bridge parapets shall be precast and of New Jersey Barrier type.
(h) Precast box culvert and precast arch bridge shall be properly designed to satisfy
the following conditions:

(i) The segments must be analysed and designed as rigid frames;

(ii) Minimum top and bottom slab thickness is 200 mm;
(iii) Minimum wall thickness is 200 mm;
(iv) Minimum height of vertical clearance to allow for inspection shall not less
than 1.25m;
(v) All joints between precast section shall be provided with tongue, groove
and lifting hooks to pick up sections;
(vi) Water proofing, geotextile fabric or wrap shall be placed over joints;
(vii) The joint exterior shall be covered with a minimum of 225 mm wide wrap
centre on the joints;
(viii) To prevent precast section from pulling apart during or after construction,
minimum four (4) longitudinal 12.7 mm diameter low relaxation
polypropylene sheathed prestressing strands with corrosion inhibitor or
other approved post-tensioning device, shall be placed in position through
preformed holes in the corners of the precast units;
 (ix) Prestressing strand with minimum 183 kN breaking load shall be provided.
Each strand shall be stressed to 137 kN or equivalent to 75% ULS;
(x) These end anchorage forces must be considered in the box culvert design;
(xi) The exposed end of the sheathed prestressing strand shall be removed
after post-tensioning. No part of the strand or the end fittings shall extend
beyond 50mm inside the hand-hold pocket. The pocket shall then be filled
with non-shrink grout;
(xii) Recommended allowable weight of precast section is below 18 metric
tonnes.

(i) Durability: The bridge and viaduct structural elements shall be designed for
enhance durability (if applicable) in accordance to The Highways Agency, UK BA
57/01
(j) The bridge and viaduct structures shall be designed for ease of inspections,
maintenance and replacements of the various parts, such as bearings, expansion
joints, etc. Suitable access facilities shall be provided and incorporated in the
bridge structure where access is not possible by normal means.
(k) Aesthetics
The bridge and viaduct structures shall be designed to satisfy for aesthetics
requirement by following REAM - GL 1/1999: Guidelines on Bridge Aesthetics.

1.5 Design Criteria

(a) Latest Malaysian, British Standards and Codes of Practice or Eurocode shall be
adopted for design of structures. The principal standards are the following:
(i) The latest version of British Standard Institution BS 5400: Steel, Concrete
and Composite Bridges.
(ii) Bridge loading shall follow The Highways Agency, UK BD 37/01: Loads for
Highway Bridges. Prestressed member should be design for Class1 under
Load Combination 1 with HA and HA+30 units HB. Load Combinations 2 to
5 is designed for Class 2 with HA and HA+45 units HB.
(iii) Integral bridges shall follow BA 42/96 Amendment No. 1: The Design of
Integral Bridges
(iv) Foundations shall follow BS 8004: Foundation.
(v) Retaining wall structures shall follow BS 8002: Code of Practice for Earth-
retaining Structures.
(vi) Reinforced Earth walls shall follow BD 3/78: Reinforced and Anchored Earth
Retaining Walls and Bridge Abutments for Embankments [Rev. 1987]
(vii) Vehicle Impact shall follow BD 60/04: Design of Highway Bridges for
Vehicle Collision Loads
 (viii) Ship impact: shall establish appropriate ship collision forces and follow the
latest version of AASHTO Guide Specification And Commentary For Vessel
Collision Design of Highway Bridges, 1991.
(ix) Expansion Joints in Bridge Decks: shall follow BD 33/94. Expansion Joints
for Use in Highway Bridge Decks. The expansion joints shall be guaranteed
by the manufacturer to have a minimum effective live of 10 years in the
prevailing climate and traffic condition.
(x) Parapet shall be in accordance to BD 52/93: The Design of Highway
Bridge Parapets and in compliance to Arahan Teknik (Jalan) 1/85 (Pindaan
1/89) Manual on Guardrail of Longitudinal - Traffic Barrier.
(b) Earthquake Loading
Earthquake loading for long-span lifeline bridges shall be taken as 1.0 in ULS and
in Load Combination 4 only. The load shall comprise the following:
Horizontal seismic loading applied in any direction at superstructure level shall be
10% of the permanent dead and superimposed dead loads + 20% of
longitudinal HA traffic loading on all notional lanes.
In considering earthquake loading no relieving effects from bearing friction will
be considered.

(c) Differential Settlement

Where differential settlement is likely to affect the structure in whole or in part, the
effects of this parameter should be taken into account.
(i) When designing a structure, the value of differential settlement shall be
taken as 12.5 mm at serviceability limit state (SLS).
(ii) The structure shall be checked for differential settlement of 38.0 mm at
ultimate limit state (ULS).

(d) Surface finishes: the surfacing designed thickness shall be 100 mm thick asphaltic
concrete.

(e) Design crack widths for reinforced concrete shall not exceed 0.10 mm in the
longitudinal or transverse direction.
(f) Bridge Clearances
(i) For bridge over river the freeboard shall be in accordance to JPS, Jabatan
Laut requirement and DJ 1/2001;
(ii) For bridge over KTMB railway lines the bridge vertical and horizontal
clearance shall be in accordance of KTM Berhad requirement;
(iii) For bridge over road the vertical and horizontal clearance shall be
approved by the relevant Road Authority.
(g) Reinforcement cover: in designing concrete members, nominal cover derived from
BS5400: Part 4 Table 13, shall be increased by 1 0mm in accordance to BD 57/95.
 (h) Prestressing anchorages shall not be located at top face of T-beams or any other
beams.

(i) Half joint shall only be allowed for temporary building of precast beams into
integral in situ crossheads.

(j) Elastomeric bridge bearings shall be of natural rubber and shall be in accordance
with the specification proposed by the Committee on Natural Rubber in
Construction, Rubber Research Institute, Malaysia.
(k) Protective coating system for exposed concrete surfaces shall consist of dual
protective system formed by two coats of silane-siloxane based primer and two
coats of solvent based methacrylate pigmented top coat. The minimum effective
life of such protective system shall be in excess of 20 years. Compulsory sample
testing of paints is required.
The material employed for the coating shall comply with the following
requirement:

Reduction in water absorption 80 % minimum @ 28 days

(ASTM C642)
Carbon dioxide diffusion resistance a minimum equivalent to
(Research Laboratories Tawood Eng. Ltd) 250m3 of air
Water vapour transmission Shall be more than
(Research Laboratories Tawood Eng. Ltd) 13g/m2/day
Reduction in chloride ion penetration 90% minimum @ 28 days
(l) Anti-corrosion protective system: The steel materials used for the bridge structures
shall follow BS 5400: Part 6. A comprehensive anti-corrosion protective system in
accordance with BS 5493 or equivalent shall be submitted. The minimum effective
life of such protective system shall be in excess of 20 years. Compulsory sample
testing of paints is required.
(m) Launching of precast elements
Utmost precautions shall be taken to eliminate any danger to workers and general
public while launching precast elements. All lifting equipment shall be designed,
such that if the primary lifting mechanism fails, a secondary mechanism will ensure
that the precast element does not fall.
Upon erection, a fail-save method shall be used to temporarily secure the precast
unit until the permanent fixing arrangements are implemented.
(n) Temporary works
The risks for each case shall have to be considered and appropriate safety factors
allowed in the design. The minimum safety factor at ULS shall be taken as 1.5 if
the safety of the general public is at risk.
(o) Drainage: drainage facility for the bridge deck shall be suitably provided and the
bridge deck shall have a minimum cross fall of 2.5%.
(p) Bridge furniture and traffic signs: shall follow that specified separately in the
relevant sections or for the road.

(q) Approach embankment for viaducts and structures shall follow Nota Teknik Jalan
1/2003 to minimised differential settlement at abutments.

(r) Reinforced earth wall shall be designed to Department of Transport Highways and
Traffic Departmental Standard BD 3/78 (Revised 1987) Reinforced and Anchored
Earth Retaining Walls and Bridge Abutments for Embankments. Reinforced earth
structures shall have a design life of 120 years.
(s) Bridge lighting: shall be of linear lighting system fixed to the bridge. The light
fixture shall be of appropriate brightness aimed at the roadway and shielded to
prevent glares to motorists. Where required by the navigational authorities,
appropriate navigational lighting aids shall be provided.
(t) A plaque shall be fixed on the outer face of the parapet or wingwall of each bridge.
The shape and dimension of the plaque shall be as approved by the Project
Director and shall be of yellow brass with bold face alphabets.
The wordings on the brass plaques shall be as follows: -
JAMBATAN : Name of bridge

TARIKH : Month and year of completion of bridge

PEREKABENTUK : Name of Designer

KONTRAKTOR : Name of Contractor

BEBAN : Design loading

RENTANG : Bridge spans, type of beam and bridge system (semi integral
/ fully integral)

ASAS : Type, size, and length of pile

(u) Footbridges
Footbridges shall follow BD 29/04: Design Criteria for Footbridges. For dual
carriageway with permitted speeds in excess of 50 km/h, a single span shall be
provided spanning both carriageways to avoid the need for support in the central
reserve. Both ramps and staircases shall be provided for access.
2.1 TERMS OF REFERENCE FOR BRIDGE ASSESSMENT PROCEDURE

2.2 Introduction

This bridge assessment procedure shall be adopted if the need statement requires
upgrading works. It involves careful consideration for the treatment of the existing stock
of structures(bridges and culverts) so as to attain the desired objectives of ensuring
structural safety, quality, serviceability, durability and economy.

2.3 Bridge Replacement Policy

The general policy is to save existing structures. The CE shall follow this Bridge
Assessment Procedure and prepare a report to cover the assessment of existing
structures.
The Objective of this report is to access :

(i) the conditions of the existing bridge based on visual inspection,

(ii) the hydraulic capacity of an existing structure based on site investigation and
discharge capacity.

(iii) the existing structures capacity based on theoretical calculation

If one or all the criteria given above are not satisfied, the existing structure will either be
replaced, widened or strengthened as deemed necessary.

2.4 Bridge Assessment Procedure

The Bridge Assessment Procedure is a nine (9) steps procedure as shown in Figure
II.1 The three types of assessment to be carried out are explained below:
2.3.1 Visual Assessment

The condition of the existing structures are to be inspected by checking defects of each
structure through visual inspection, giving particular attention to primary members such
as longitudinal beams, cross heads and abutments. The defects shall be divided to
(i) Material defects

These includes spalling of concrete, corrosive of steel reinforcement and abrasion

of piers and abutments.

(ii) Structural Defects

Structural defects are caused by the inability of the structural member to resist
the load imposed on it and can be in the form of cracks, settlement or
deformation
(iii) Hydrological Defects

This includes silting and erosion due to fluctuation of water level and inadequate
discharge capacity of the existing section.
 2.3.2 Hydrological Assessment

The aim of this assessment is to ensure that the existing structure provides adequate
opening for the designed flood frequency discharge. Also the foundation structure is to
be checked for scouring effects.

2.3.3 Analytical Assessment

a) The loading shall be JKR Specification for Bridge Live Loads

(i) Long Term Axle Loads(LTAL) combined with KEL
(ii) Special Vehicle (SV20) loading

b) Method of analysis should ideally take into account of all the significant aspects
of behaviour of a structure governing its response to loads and imposed
deformations.

2.3.4 Structural Member Resistance

a) Evaluation Code shall follow

(i) BD 21/93 : The Assessment of Highway Bridges And Structure,

Department of Transport UK.
(ii) BD 44/90 : The Assessment Department Of Transport UK.
of Concrete Highway Bridges and Structures.

b) Partial /Load Factors

Dead Load = 1.15

Superimposed Dead Load If premix was measured Live Load
= LTAL
1.75
Live Load SV = 1.25
= 1.50
= 1.30

c) For material Strength Without Drawings (Unknown)

fy = 230 N/mm2 =  = 1.10

ms
fyv = 230 N/mm2 =  = 1.15
mv
fcu = 30 N/mm2 =  = 1.20
mc

d) Calculation of Member Resistance by Statistical Method

This method shall be used to obtain percentage of steel for reinforced concrete
bridges without flexural reinforcement details. The use of this method is
restricted to:

i. Simply supported reinforced concrete bridges

- Bridges in Peninsular Malaysia
- bridges constructed between 1950 and 1972
- bridges spanning between 6-15 metres.
 The Formula is:

% steel = 0.015 x Rcindex -

0.20 Rcindex = 100 x S. L 1.326

W. D2

S = The girder spacing(mm); L = Span length (mm)

W = The girder width (mm); D = The effective depth (mm) - 0.9 of the total depth

Rating System
The load carrying capacity of a bridge is assessed based on the ratio of the available
resistance of a member to the effective of live load

Rating = ФR-αD
αL

ФR = Factored resistance of a member

αD = Effect of the factored dead load on a member

αL = Effect of the factored live load for LTAL

SV Rating = 20. ФR-αD

αLsv
where αLsv = effect of the factored SV20 loading on the member

Decision Making
Widen when Rating > 0.8 LTAL
Replace when rating < 0.8 LTAL

2.5 Reporting On the Bridge Assessment

The detail report shall be submitted in writing to JKR within 2 weeks of the assessment
being done or otherwise as agreed in writing .
It shall include a summary of the CE recommendation as shown in Figure ll.2
 FIGURE II.1: BRIDGE ASSESSMENT
PROCEDURE

STEP 1
Desk Study

STEP 2
Categorised bridges into:
a. bridges with adequate drawings
b. bridges without drawings

STEP 3
Visual inspection and condition assessment

STEP 4
Hydraulic assessment (if over river)
Satisfactory? No

Seek methods to improve the hydraulic characteristics

Yes

Improveme
Improvement possible nt not
possible

Discussion and seek further advice from JKR and JPS

STEP 5
Structural analysis

Hydraulic
characteristic
Recommend for
Bridge with drawings Bridge without s acceptable replacement
drawings

STEP 6 STEP 6A
Structural capacity determination Identification of bridges suitable for using the JKR statistical
method

Bridges suitable for JKR statistical method

STEP 7A,8A,9A
Discussion and seek further advise from JKR

Adequate? RETAIN

Yes

No
STEP 7
Determine material properties Yes

STEP 9
Load limitation/weight restriction
Strengthening/upgrading
Adequate?
Load Testing
STEP 8 No Replacement
Reassess structural capacity

11 10
 FIGURE 11.2: SUMMARY OF CE
RECOMMENDATION

No. Structure Bridge Span Carriageway Year Consultant's Report JKR Comments
No/River Consultant's
Type Length(m) Width(m) Built Hydraulic Condition Analytical Recommendation Opinion
Name Action

11