Retrofit Bridge Rail Design and Testing for a Historic Texas Steel Truss Bridge

The State Loop 481 steel truss bridge over the Llano River in Junction, Texas, is classified as a historic structure. The bridge is approximately 1,423 ft long and has a railing that attaches directly to the steel truss members and does not meet the current AASHTO Test Level 2 (TL-2) strength requirements. Many supporting truss members were not adequate to resist TL-2 crash force. The purpose of this research was to design a crashworthy retrofit bridge rail that met the current AASHTO TL-2 strength requirements without overstressing the supporting truss members. The new design maintains the historic appearance of the structure. This paper presents details of the new bridge rail design and an analytical procedure for determining the magnitude of force transmitted to the supporting truss members. Crushable-pipe blockouts located between the new retrofit rail design and the truss members were developed as part of this research and were used to minimize the crash force transmitted to the steel truss members. The new bridge rail design was successfully crash tested in accordance with the TL-2 requirements of NCHRP Report 350. A bridge rail expansion splice was developed for the new bridge rail design and was successfully crash tested in accordance with the Test Level 3 requirements of NCHRP Report 350. This paper presents the results of this research, details of the expansion splice, the new bridge rail design, the design procedure, and the results of the crash testing.