511ELASTOMERIC BEARINGS

371

510-C Bridge Concrete Superstructure, *, **, *** - per lump sum 510-E Grooving Concrete Bridge Decks - per square yard {square meter} 510-G Mass Bridge Concrete Substructure - per cubic yard {cubic meter} 510-H Mass Bridge Concrete Superstructure, *, **, *** - per lump sum 510-J Bridge Barrier Rail, Type ____ - per linear foot * Station Number, Bridge Identification Number (BIN), Ramp Number, etc. ** Lane, if applicable *** Approximate quantity of superstructure concrete in cubic yards {cubic meters} ELASTOMERIC BEARINGS

511.01Description

This Section shall cover the work of furnishing and installing elastomeric bearings for all types of bridge girders. An elastomeric bearing shall consist of at least a single layer of elastomer and may consist of a possible combination of elastomeric layer(s), internal steel sheet laminate(s), PTFE layer, bearing and/or sole plates, and a stainless steel plate.

511.02Materials

All elastomeric bearings furnished for use shall be from an approved producer listed on List I-17, PRODUCERS OF ELASTOMERIC BEARING PADS, of the Department's MSDSAR manual. Refer to Subarticle

106.01(f) and ALDOT-355 concerning this list

Elastomeric bearings shall be fabricated to conform with the material requirements given on the Plans and in Section 837.

511.03Construction Requirements

Unless noted otherwise on the plans or in these specifications, Shop Drawings for the elastomeric bearings shall be submitted to the Bridge Engineer for approval. Shop Drawings will not be required for the elastomeric bearings for precast concrete bridge components furnished under Section 512. The elastomeric bearings will be identified on the plans by Type (Type 1, 2, 3, 4, or 5) and may be further identified by a Mark (Mark B1, B2, VB1, etc.). Rust that occurs on the portions of bearing plates that are left ungalvanized for welding shall be cleaned to bare metal prior to welding. All exposed surfaces of the sole plate, all uncoated surfaces of the bearing plate and all weld metal shall be coated after welding with galvanizing repair paint that meets the requirements given in SECTION 855.

511.04Method of Measurement

The elastomeric bearings will be measured per each for each type of bearing. The bearings measured for payment do not include the randomly selected samples for testing.

511.05Basis of Payment

The unit price bid per bearing shall include all costs for equipment, materials (including bearing plates, sole plates, PTFE, and stainless steel plates), cleaning, painting, labor, bearings furnished for sampling and testing, shop drawings, and all incidentals necessary to furnish and install the complete bearing assembly.

511-A Elastomeric Bearing Type * (Mark ** ) - per each * Bearing Type (1, 2, 3, 4, or 5) ** Optional Bearing Mark (B1, B2, VB1, etc.) PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS 372

PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS

512.01Description

This Section shall cover the work of furnishing and installing precast non-prestressed concrete bridge members.

512.02Materials

Material requirements for the production of precast non-prestressed concrete bridge members are given in this Section and also in ALDOT-367 "Production and Inspection of Precast Non-Prestressed and Prestressed Concrete".

Reinforcing steel shall meet the requirements given in SECTION 835. Reinforcing steel shall be Grade 60 {Grade 420}.

The precast concrete producer shall establish the proportion of materials following the guidelines given in ALDOT-170, "Method of Controlling Concrete Operations for Structural Portland Cement Concrete " and ALDOT-367, “Production and Inspection of Precast Non-Prestressed and Prestressed Concrete”. The concrete producer shall submit the proposed concrete mixture proportions to the Materials and Tests Engineer for approval following the guidelines given in ALDOT-170. The distribution of the approved concrete mixture shall be in accordance with the requirements given in ALDOT-170 and ALDOT-367. Any changes of the materials and/or proportions of the approved concrete mixture, excluding chemical admixture dosages, shall require a concrete mixture re-submittal and approval.

The 28-day compressive strength of bridge substructure members (bent caps, abutment caps, panels, etc.) shall be 3000 psi {21 MPa} unless the 28-day compressive strength is shown otherwise on the plans. The 28-day compressive strength of bridge superstructure members (deck, curb, barrier rail, etc.) less than 20 feet {6 meter} in length shall be 4000 psi {28 MPa} unless the 28-day compressive strength is shown otherwise on the plans. The 28-day compressive strength of bridge superstructure members (deck, curb, barrier rail, etc.) 20 feet {6 meter} and over in length shall be 5000 psi {35 MPa} unless the 28-day compressive strength is shown otherwise on the plans

The mixture design shall be based on the following requirements: REQUIRED DESIGN PROPERTIES OF CONVENTIONAL CONCRETE MIXTURES Property Requirement Minimum Cementitious Factor (Lbs/Yd 3) {kg/m3} 550 {330} Maximum Water/Cementitious Material Ratio 0.45 Maximum Slump (prior to admixture) (in) {mm} 4.0 {100} The maximum allowable total air content is 6.0 % by volume. The concrete mixture design shall be based on a target total air content of 4.5 %. Chemical Admixtures for the production of conventional concrete shall be selected from List II-1 of the Department’s "Materials, Sources, and Devices with Special Acceptance Requirements" Manual. Refer to Subarticle 106.01(f) and ALDOT-355 concerning this list. Chemical admixtures may be used to increase the slump of the concrete to a maximum of 9 inches {225 mm} if this is proposed in the mixture design submittal and approved for inclusion in the mixture. The approved water/cementitious material ratio shall not be exceeded in order to increase the slump. PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS 373

Self-consolidating concrete (SCC) for the production of precast non-prestressed concrete bridge members shall meet the additional requirements of this Item. SCC is utilized to fill the formwork and encapsulate the reinforcing steel without, or with only minimal, applied vibratory consolidation. The concrete producer shall establish the SCC mixture proportion in accordance with the guidelines given in ALDOT 170 with the exception that the producer shall determine the SCC mixture proportion to meet the required design properties given in the following table.

REQUIRED DESIGN PROPERTIES OF SCC MIXTURE Properties shall be measured from a minimum size batch of 3 cubic yards {2 cubic meters}. Property Requirement Compressive Strength at 28 days The compressive strength shall meet Item 512.02(c)2. Cementitious Materials Content Minimum 600 lb/yd3 {355 kg/m3} of concrete. Water/Cementitious Materials Ratio Maximum 0.45. Nominal Aggregate Size Maximum ¾ inches {20 millimeters}. Fine/Total Aggregate Ratio 0.45 to 0.55 by volume. Total Air Content Maximum 6.0 % by volume. The design of the mixture shall be based on a target total air content of 4.5 %. Temperature Freshly mixed concrete temperature as limited in ALDOT-367. Slump Flow1 Minimum 25 inches {635 millimeters} and maximum 29 inches {735 millimeters}. Passing Ability1 Difference between slump flow and J-Ring flow 3.0 inches {75 millimeters} or less. Stability1 VSI 1.0 or less. Robustness Slump flow 29 inches {735 millimeters} or less and VSI 1.0 or less. NOTE: 1. Test shall be completed within 10 minutes after completion of mixing. Chemical Admixtures for the production of SCC shall be selected from List II-1 of the Department’s "Materials, Sources, and Devices with Special Acceptance Requirements" Manual. Refer to Subarticle 106.01(f) and ALDOT-355 concerning this list. Approved viscosity modifying admixtures (VMA) may be used as a part of the chemical admixtures if they are shown in the approved mixture design.

The cementitious materials used in the concrete mixture shall meet the requirements given in Sections 806 and 815. Fly ash, ground granulated blast furnace slag, and microsilica can be substituted for a portion of portland cement. Various options of maximum percent allowable mineral admixture substitutions for portland cement are defined in the following table. PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS 374

MAXIMUM PERCENT OF ALLOWABLE MINERAL ADMIXTURE SUBSTITUTION FOR PORTLAND CEMENT (BY WEIGHT) Substitution Option Class C or Class F Fly Ash Ground Granulated Blast Furnace Slag Microsilica 1 30 % - - 2 - 50 % - 3 - - 10 % 4 20 % - 10 % 5 20 % 30 % -

512.03Construction Requirements

The precast concrete bridge member manufacturing plant shall be certified by either the Precast/Prestressed Concrete Institute (PCI) Plant Certification Program or the National Precast Concrete Association (NPCA) Plant Certification Program. Certification of plants under PCI shall be at least Category B1 (Precast Bridge Products). The manufacturer shall submit proof of the plant certification to the Materials and Tests Engineer prior to the start of production. The manufacturing plant shall have on site, at the time of manufacturing bridge components for ALDOT, at least one technician that is certified as an ALDOT Concrete Technician. This technician shall also have a NPCA certification or be certified as PCI Level I/II. The manufacturer shall submit proof of this certification to the Materials and Tests Engineer prior to the start of production and during production when required by the Engineer. The manufacturer's laboratory and laboratory personnel shall be qualified in accordance with the requirements given in ALDOT-405, "Certification and Qualification Program for Concrete Technicians and Concrete Laboratories".

The producer’s Quality Control (QC) technician shall be responsible for concrete Sampling and testing. The QC technician shall determine and document the point of sampling and testing and the testing schedule for each line of production. Sampling and testing shall be done as close as possible to the casting bed and in accordance with the requirements of ALDOT-367.

Conventional concrete shall be in compliance with the requirements given in the following table during production. REQUIRED PROPERTIES OF CONVENTIONAL CONCRETE MIXTURES DURING PRODUCTION Property Requirement Compressive Strength at 28 days The compressive strength shall meet Item 512.02(c)2 Temperature Freshly mixed concrete temperature as limited in ALDOT-367 Total Air Content Maximum 6.0 % by volume. Slump Maximum 4.0 in {100 mm} without chemical admixtures Maximum 9.0 in {225 mm} with chemical admixtures

SCC shall be in compliance with the requirements given in the following table during production. PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS 375

REQUIRED PROPERTIES OF THE SCC MIXTURE DURING PRODUCTION Property Requirement Compressive Strength at 28 days The compressive strength shall meet Item 512.02(c)2. Temperature Freshly mixed concrete temperature as limited in ALDOT-367. Total Air Content Maximum 6.0 % by volume. Slump Flow Minimum 25 inches {635 millimeters} and maximum 29 inches {735 millimeters}. Stability VSI 1.0 or less, or Sieved fraction 7.5 % or less for gradation with ½” nominal aggregate size or smaller, or sieved fraction 15 % or less for gradation with ¾” nominal aggregate size. 1 NOTE: 1. The sieve fraction is determined by the Sieve Stability Test in accordance with ALDOT-452.

The roadway surface of bridge deck span sections shall be finished with either a wood float finish or with a broom finish done with a broom with medium to stiff bristles. A broom finish shall be applied in a transverse direction and shall penetrate the surface approximately 1/8 of an inch. Curb and barrier rail sections shall have a Class 3 surface finish in accordance with the requirements given in Section 501. All other surfaces shall have a Class 1 surface finish in accordance with the requirements given in Section 501.

The Contractor shall be fully responsible for handling, storing and transporting precast concrete bridge members in a manner that will prevent damage to the members. Members shall be lifted and stored in an upright position. Lifting hooks or similar devices for lifting shall be placed at points close to each end of each member or at the locations shown on the plans. Devices shall be of sufficient strength and embedment to provide safe handling of the members. Blocking under units during storage and handling shall be placed to prevent damage. Precast concrete bridge members shall be held at the plant for a minimum of 4 days after casting. Precast concrete bridge members shall not be transported until the minimum 28-day compressive strength is obtained and verified by test cylinders.

Members that are damaged in any way shall be replaced or repaired without extra compensation.

Deck members shall be installed so that the difference in the surface of the deck across adjacent members does not exceed 1/4 of an inch {6 mm}. Deck members shall be replaced without extra compensation if the difference in the surface is not within the allowable 1/4 of an inch {6 mm} difference. Members not meeting the installation tolerance may be installed in other locations in the structure if this results in an acceptable deck surface. Deck members shall be bolted together as shown on the plans to provide snug tight fit. Beveled washers shall be provided if the flat washers, bolt heads and nuts are not in full bearing on each other after tightening. Snug tight is defined as the tightness that can be produced by one or two solid blows from an impact wrench or by full effort of a person using an ordinary 2 foot {610 mm} spud wrench. The threads of the bolts shall be burred to prevent removal after the members have been acceptably bolted together. The concrete keyway shall be filled with concrete after the members have been acceptably installed. The keyway shall be filled with a 1:2:3 concrete mixture, by weight {mass}, of cement, fine aggregate, and coarse aggregate, respectively. The maximum size of the coarse aggregate shall be 3/8 of an inch {9.5 mm}, and the maximum amount of water allowed shall be 6 gallons per 100 pounds {1 liter per 2 kg} of cement.. The keyways shall be filled in accordance with the following: PRECAST NON-PRESTRESSED CONCRETE BRIDGE MEMBERS 376

of placement; - The mixture shall be retempered by remixing the concrete without additional water just prior to placing; - The concrete mixture shall be placed in the keyway, tamped, and packed as necessary to ensure complete filling of the joint; - The exposed surface of the newly place concrete keyway shall be struck to the same elevation as the adjacent deck sections; - The surface shall be given a wood float finish - The concrete keyway shall be cured as per Subarticle 501.03(j).

All piling shall be properly aligned (transversely and longitudinally) prior to the establishment of the pile cutoff elevations. Gaps anywhere between the cap anchor plate and the top of the pile are unacceptable without adequate correction. The Contractor shall submit a written procedure for providing a structurally acceptable connection when a gap is greater than 3/16 inch {4 mm}. The corrective procedure shall be submitted in accordance with the requirements for Working Drawings given in Article

105.02

Where all gaps between the cap anchor plate and the top of the pile are less than or equal to 3/16 inch {4 mm}, attachment welds shall be provided in accordance with the requirements given in the following table. WELD REQUIRED FOR THE ATTACHMENT OF PRECAST CONCRETE CAP ANCHOR PLATE TO THE TOP OF A STEEL PILE Size of Largest Gap Anywhere At Top of Pile Size of Fillet Weld Required All Around the Top of the Steel Pile Full Contact-No Gap 1/4 inch {6 mm} (per Standard Details on Plans) Less Than or Equal to 1/16 inch {2 mm} 1/4 inch {6 mm} (per Standard Details on Plans) Less Than or Equal to 1/8 inch {3 mm} 5/16 inch {8 mm} Less Than or Equal to 3/16 inch {4 mm} 3/8 inch {10 mm} The connection between the top of the pile and the steel plate embedded in the cap shall be made by a welder that is ALDOT certified 4F (qualified for fillet welding in the overhead position) using the manual Shielded Metal Arc Welding (SMAW) method. Welding shall be done in accordance with the requirements given in Section 836.

Cranes shall not be placed on a bridge deck unless approved by the Engineer. The Contractor shall submit a placement plan for review prior to placing a crane on a bridge deck. The placement plan shall be submitted in accordance with the requirements given in Section 510.

All exposed surfaces of piles shall be painted in accordance with the requirements given in Sections 505 and 521. The surface of the piling that is in contact with the abutment panels shall be painted with the coating applied to the other surfaces of the piling or with a System 3 coating if the abutment panels are installed prior to the painting of the other surfaces.

512.04Method of Measurement

Precast concrete bridge members will be measured per each for each type and size of member.

512.05Basis of Payment

A precast concrete member will be paid for at the contract unit price for the required type and size (depth, width, and length). This unit price shall be full compensation for manufacturing, delivery and installation, accessories, all items cast into the concrete, tie bolts, expansion materials, cover concrete over fittings, grout and grouting, surface finishing and for all other materials, equipment, labor, and incidentals required to make the bridge member a part of the completed bridge. Structural steel, handrail and bearings will be paid for under other items of work.