Design Manual for Roads and Bridges

Highway Structures & Bridges

Design

CD 359
Design requirements for permanent soffit
formwork
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(formerly BA 36/90, with IAN 131/11)

Revision 0

Summary
This document sets out design requirements for permanent soffit formwork for bridges.

Application by Overseeing Organisations

Any specific requirements for Overseeing Organisations alternative or supplementary to those given in this document
are given in National Application Annexes to this document.

Feedback and Enquiries

Users of this document are encouraged to raise any enquiries and/or provide feedback on the content and usage
of this document to the dedicated Highways England team. The email address for all enquiries and feedback is:
[email protected]

This is a controlled document.

 CD 359 Revision 0 Contents

Contents
Release notes 2

Foreword 3
Publishing information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Contractual and legal considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction 4
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assumptions made in the preparation of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mutual Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Abbreviations 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Terms and definitions 6

1. Scope 7
Aspects covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of GG 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2. Design requirements 8
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Participating formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Non-participating formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3. Actions during execution 10

4. Normative references 11

5. Informative references 12

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 CD 359 Revision 0 Release notes

Release notes
Version Date Details of amendments
0 Mar 2020 CD 359 replaces BA 36/90 and IAN 131/11. The full document has been
rewritten to make it compliant with the new Highways England drafting rules.
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 CD 359 Revision 0 Foreword

Foreword
Publishing information
This document is published by Highways England.
This document supersedes BA 36/90 and IAN 131/11, which are withdrawn.

Contractual and legal considerations

This document forms part of the works specification. It does not purport to include all the necessary
provisions of a contract. Users are responsible for applying all appropriate documents applicable to
their contract.
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 CD 359 Revision 0 Introduction

Introduction
Background
This document sets out design requirements and associated implications when adopting permanent
formwork for soffits of bridge decks.

Assumptions made in the preparation of the document

The assumptions made in GG 101 [Ref 9.N] apply to this document.

Mutual Recognition
Where there is a requirement in this document for compliance with any part of a British Standard or
other technical specification, that requirement may be met by compliance with the Mutual Recognition
clause in GG 101 [Ref 9.N].
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 CD 359 Revision 0 Abbreviations

Abbreviations

Abbreviation Definition
CIRIA Construction Industry Research and Information Association
GRC Glassfibre reinforced concrete
GRP Glass reinforced plastic
MCHW Manual of Contract Documents for Highways Works
PSS Profiled steel sheeting
SHW Specification for Highway Works
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 CD 359 Revision 0 Terms and definitions

Terms and definitions

Term Definition
Permanent formwork Structure that is used to contain the placed concrete in order to
mould it into the required dimensions and support it until it is
able to support itself.
Participating permanent formwork Permanent formwork which is a structurally participating
element forming an integral connection with the permanent
works.
Non-participating permanent Permanent formwork which is not structurally participating in the
formwork permanent works.
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 CD 359 Revision 0 1. Scope

1. Scope
Aspects covered
1.1 This document shall be used for the design of permanent formwork for soffits of bridge decks.

Implementation
1.2 This document shall be implemented forthwith on all schemes involving permanent soffit formwork on
the Overseeing Organisations' motorway and all-purpose trunk roads according to the implementation
requirements of GG 101 [Ref 9.N].

Use of GG 101
1.3 The requirements contained in GG 101 [Ref 9.N] shall be followed in respect of activities covered by
this document.
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 CD 359 Revision 0 2. Design requirements

2. Design requirements
General requirements
2.1 Permanent formwork and in-situ concrete required for the deck shall satisfy all requirements for
strength, serviceability, fatigue, composite action and durability given in BS EN 1992-2 [Ref 5.N], BS
EN 1993-2 [Ref 6.N] and BS EN 1994-2 [Ref 7.N] as relevant.
NOTE 1 Specification requirements for permanent formwork are given in MCHW Series 1700 [Ref 3.I].
NOTE 2 Additional guidance on the design of permanent formwork is given in CIRIA C558 [Ref 5.I], SCI P382
[Ref 4.I], SCI P339 [Ref 1.I] and CS 030 [Ref 2.I].
2.2 The design of precast reinforced concrete plank permanent formwork (floor plates) shall be in
accordance with BS EN 15050 [Ref 10.N].
2.3 The design shall allow for actions during execution and in service.
2.4 The design shall allow for the construction sequence and the behaviour of the formwork during
construction.
2.5 Deflection limits for the permanent formwork shall be determined taking into account appearance and
the movement of the formwork relative to the reinforcement.
2.5.1 Deflection of the permanent formwork between completion of concreting and four hours later, with due
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allowance for the effect of creep, should not exceed 1/300 of the span.
2.5.2 The formwork may be pre-cambered by not more than 1/150 of the span of the formwork unit.
2.6 Reinforcement cover shall satisfy the design requirements after all deflection of the permanent
formwork during concreting and setting of the concrete has occurred.
2.7 Cover requirements shall be in accordance with A.3 of BS 8500-1 [Ref 3.N] and the relevant provisions
for participating and non-participating formwork below.

Participating formwork
2.8 Where participating reinforced concrete plank permanent formwork systems are used, the relevant
exposure class shall be applied to the concrete plank itself for cover requirements and concrete quality.
2.8.1 For bridge deck soffits more than five metres vertically above the carriageway, the exposure class for
the concrete plank should be taken as XD1 in accordance with BS 8500-1 [Ref 3.N].
2.8.2 A minimum of 20 mm cover should be provided from the upper surface of the concrete plank to the
reinforcement in the in-situ concrete slab above.

Non-participating formwork
2.9 Where the permanent formwork is non-participating, any potential adverse effect of differential
shrinkage or composite action shall be considered.
NOTE Typical non-participating permanent formwork used for bridge decks include glassfibre reinforced
concrete (GRC), glass reinforced plastic (GRP) and profiled steel sheeting (PSS) systems.
2.10 When PSS permanent formwork systems containing indentations forming a potential shear connection
with the in-situ concrete are used, it shall be demonstrated by calculation or testing that the detail is not
likely to lead to fatigue cracks during the lifetime of the bridge.
2.11 Where non-participating permanent formwork systems are used, the relevant exposure class shall be
applied to the in-situ concrete above the permanent formwork for cover requirements and concrete
quality, ignoring the presence of the permanent formwork.
2.11.1 For bridge deck soffits more than five metres vertically above the carriageway, the exposure class for
the in-situ concrete above the non-participating permanent formwork should be taken as XD1 in
accordance with BS 8500-1 [Ref 3.N].

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 CD 359 Revision 0 2. Design requirements

2.11.2 A minimum of 20 mm cover should be provided from the upper surface of the non-participating
permanent formwork to the reinforcement in the in-situ concrete slab above.
2.11.3 Where ribbed glass reinforced plastic (GRP) permanent formwork systems are used and where the
GRP ribs protrude into the concrete, the cover should be measured from the horizontal GRP/concrete
interface, provided that at least 20 mm is also provided between the top of the rib and the nearest
reinforcement.
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 CD 359 Revision 0 3. Actions during execution

3. Actions during execution

3.1 Participating formwork shall be designed to support actions during execution and permanent actions in
accordance with BS EN 1991-1-6 [Ref 1.N] and BS EN 1991-1-1 [Ref 4.N] respectively.
NOTE Participating formwork forms part of the permanent structural elements and is therefore subject to the
same design requirements as the permanent works.
3.2 Non-participating formwork shall be designed to support actions during execution and permanent
actions in accordance with either BS EN 1991-1-6 [Ref 1.N] and BS EN 1991-1-1 [Ref 4.N]
respectively, or BS 5975 [Ref 2.N] and BS EN 12812 [Ref 8.N].
NOTE Non-participating formwork is part of the temporary works and therefore the permanent design
considerations can be deemed not to comply provided the criteria for temporary works are met.
3.3 Irrespective of the design method employed, in no case shall the factor of safety against collapse of
formwork during execution, based on unfactored actions and resistances, be less than 2.0.
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 CD 359 Revision 0 4. Normative references

4. Normative references
The following documents, in whole or in part, are normative references for this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.

Ref 1.N BSI. BS EN 1991-1-6, 'Actions on structures. General actions. Actions during
execution.'
Ref 2.N BSI. BS 5975, 'Code of practice for temporary works procedures and the permissible
stress design of falsework.'
Ref 3.N BSI. BS 8500-1, 'Concrete. Complementary British Standard to BS EN 206. Method
of specifying and guidance for the specifier.'
Ref 4.N BSI. BS EN 1991-1-1, 'Eurocode 1 - Actions on Structures - Part 1-1: General
actions- Densities, self weight, imposed loads for buildings'
Ref 5.N BSI. BS EN 1992-2, 'Eurocode 2. Design of concrete structures. Part 2: Concrete
bridges. Design and detailing rules'
Ref 6.N BSI. BS EN 1993-2, 'Eurocode 3. Design of steel structures Part 2: Steel bridges'
Ref 7.N BSI. BS EN 1994-2, 'Eurocode 4. Design of composite steel and concrete structures.
Part 2: General rules and rules for bridges'
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Ref 8.N BSI. BS EN 12812, 'Falsework. Performance requirements and general design.'
Ref 9.N Highways England. GG 101, 'Introduction to the Design Manual for Roads and
Bridges'
Ref 10.N BSI. BS EN 15050, 'Precast concrete products. Bridge elements.'

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 CD 359 Revision 0 5. Informative references

5. Informative references
The following documents are informative references for this document and provide supporting
information.

Ref 1.I The British Constructional Steelwork Association. Iles, DC. SCI P339, 'Design Guide
for Ladder Deck Bridges.'
Ref 2.I Concrete Society. CS 030, 'Formwork - a guide to good practice.'
Ref 3.I Highways England. MCHW Series 1700, 'Manual of Contract Documents for Highway
Works, Volume 1 Specification for Highway Works - Series 1700 Structural Concrete'
Ref 4.I The Steel Construction Institute (SCI). Steel Bridge Group. SCI P382, 'Model Project
Specification for the Execution of Steelwork in Bridge Structures.'
Ref 5.I CIRIA. R. G. Wrigley. CIRIA C558, 'Permanent formwork in construction.'
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