Shear Studs and Deck Pans

[brokenpile]

We have a steel tube truss bridge 14' wide by 130' long that has floor beams 7'-2" o.c.Bridge had to be galvanized and painted so the nelson studs where installed before galvanizing 1' o.c. across the floor beams.Bridge company sent out 2" non composite 20 gauge deck pans which we flame cut holes so the deck pan would fit over the nelson studs.RE took a fit and we also discovered that the deck pans were to light for the thickness of the concrete deck which is 7 7/8".Bridge company recalculates to use an 2" 18 gauge deck pan and to use a hole saw to cut the holes to fit over nelson studs.Problem is that the Owner is still concerned about cutting holes in the deck pans since they are designed for 3 span.The deck pan company doesn't offer any information about cutting holes in the deck pans over the floor beams as to you can or can't.Other option is to cut studs off and then weld new ones on through the pans.Anyone have any experience with this issue?Mind you the nelson studs were not needed for the steel truss bridge design but because they were in the boiler plate specifications owner still want them to be use even though the bridge doesn't require them structuraly.

 

[TXStructural]

I'd be inclined to use a deck which will single span the space between trusses so it can be installed on either side of studs. Bridge deck forms frequently have flattened ends, so they can rest on supports and retain the wet concrete. If the deck is already there, and is capable only of three span conditions, cutting a hole every foot should be a fairly reasonable solution.

However, studs are post-installed in order to be certain that the studs coincide properly with the deck ribs. Are you certain this same condition can be met?

 

[brokenpile]

Bridge Company increased the deck pans to 18 gauge so we would meet single span requirements and we drilled holes in the pans to fit over the shear studs which do fall in the valleys of the pans.