I was at TRB when a bit of a report was given by FHWA and one of the consultants who worked on the investigation. The gussets were 1/2" when similar gussets elsewhere in the bridge were 1", which is what got people looking at their design to begin with.
Because the original design calcs are gone, there is no way to know if it was a design error or a drafting error. The investigator said because of the particular distribution of the construction loads, that node in the bridge was seeing the highest load it had ever been under before. That's what was different.
Everything was a factor; if the bridge hadn't been redone over the years with more concrete barriers and more traffic, the undersized gussets might have survived (then again, maybe not, considering the particulars of the construction load distribution), but if the gussets hadn't been undersized, all the concrete barriers, increased traffic, and construction loads would have been fine.
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