506-5 Basis of Payment:
The accepted quantities of each type and size of underdrain measured as provided above, will be paid for at the contract unit price per linear foot, complete in place. The contract price shall be full compensation for furnishing all labor, materials, tools, equipment, and incidentals involved in installing perforated pipe, drainage fabric, and aggregate material as specified in the plans and specifications, and as directed by the Engineer. The contract unit price shall also include connecting outlets to drainage facilities, welded metal covers, and any necessary excavation and backfill. SECTION 507 EDGE DRAINS:
507-1 Description:
The work under this Section shall consist of furnishing all labor, equipment, and materials to construct an edge drain system in accordance with the details shown on the project plans and as directed by the Engineer. The edge drain system shall include installation of plastic pipe edge drains and edge drain outlets, vents, and cleanouts, and furnishing and placing permeable drain material, filter fabric , and miscellaneous appurtenances as shown on the plans and as specified in these specifications and Special Provisions.
507-2 Materials:
507- 2.01 Pipe Materials: Certificates of Compliance conforming to the requirements of Subsection 106. 05 of the specifications shall be submitted for all pipe material. P ipe and pipe fittings for edge drains and edge drain outlets, vents, and cleanouts shall be of the size shown on the project plans. Pipe installed in trenches to be backfilled with asphalt -treated permeable material shall be polyvinyl chloride (PVC) 90 degrees C electric plastic conduit, EPC -40 or EPC -80, conforming to the requirements of NEMA Specification TC -2. All pipe for edge drains and edge drain outlets, vents, and cleanouts shall, at the contractor's option, conform to one of the following:
A.PVC 90 degrees C electric plastic conduit, EPC -40 or EPC - 80, conforming to the requirements of NEMA Specification TC-2; or
B.PVC plastic pipe, Schedule 40 or Schedule 80, conforming to the requirements of ASTM D1785. The type, grade, and TABLE OF CONTENTS INDEX design stress designation of the pipe shall be either 1120, 1220, 2120, 2116, 2112, or 2110 as specified in ASTM D1785. Pipe shall be straight -end or bell -end. Bell and sockets shall conform to the requirements of ASTM D2672 except for the marking. In addition, pipe designated as slotted on the plans shall have three rows of slots in the pipe. The rows shall be in the longitudinal direction of the pipe and the slots shall be cut in the circumferential direction of the pipe. The three rows shall be spaced equally around the circumference of the pipe. Each row shall have 22 ± one uniformly spaced slot s per linear foot of pipe. The slots shall be 0.045 to 0.065 inches wide and of such length as to provide a minimum of 2.00 square inches of slot opening per linear foot of pipe. Other suitable configurations of slots which provide drainage equal to or better than the above slot requirements may be used if approved in writing by the Engineer. Except as otherwise provided for wye fittings, fittings for PVC 90 degrees C electric plastic conduit shall conform to the requirements of NEMA Specification TC -3, and the fittings for PVC plastic pipe shall be socket -type fittings conforming to ASTM D2467 f or Schedule 80 pipe and ASTM D2466 for Schedule 40 pipe. Wye fittings shall be shop fabricated from pipe conforming to the requirements for the type of edge drain pipe installed. The fitting shall provide an unobstructed passageway through both legs of t he wye. 507- 2.02 Treated Permeable Material: Permeable material for edge drains shall be asphalt treated permeable material or cement treated permeable material. The type of treatment (asphalt or cement) for the permeable material shall be at the contract or's option. Treated permeable material shall be stored, proportioned, and mixed in accordance with the requirements of these specifications.
A.Asphalt Treated Permeable Material: Aggregates shall be clean and free from decomposed materials, organic material, and other deleterious substances. The gradation of the aggregate shall meet the following requirements when tested in accordance with Arizona Test Method 201: TABLE OF CONTENTS INDEX Sieve Size Percent Passing 1 inch 100 3/4 inch 90 - 100 1/2 inch 35 - 65 3/8 inch 20 - 45 No. 4 0 - 10 No. 8 0 - 5 No. 200 0 - 2.0 Aggregate shall conform to the following quality requirements prior to the addition of asphalt: Tests Test Method Requirement Fractured Coarse Aggregate Particles Arizona Test Method 212 Min. 90% Abrasion AASHTO T 96 500 Rev., Max. 45% Sand Equivalent AASHTO T 176 Min. 55 The combined bulk specific gravity range for the aggregate shall be 2.35 to 2.85. The combined water absorption range for the aggregate shall be zero to 2.5. Asphalt to be mixed with the aggregate shall be PG 64- 16 unless otherwise specified or approved by the Engineer. Aggregates and asphalt for asphalt treated permeable material shall be stockpiled, proportioned, and mixed in the same manner provided for in Subsection
406-6 of the specifications, except as follows:
The aggregate need not be separated into sizes. The temperature of the aggregate before adding the asphalt binder shall not be less than 275 degrees F nor more than 325 degrees F. Asphalt treated permeable mate rial stored in excess of two hours shall not be used in the work. The aggregate shall be combined with 2.5 percent paving asphalt by weight of the dry aggregate. After testing samples of the contractor's proposed aggregate supply, the Engineer may order an increase or decrease in the target asphalt content. If such increase or decrease is ordered, and the increase or decrease shall be less than 0.5 percent by weight of the dry aggregate, no additional compensation for this increase or decrease of asphalt content will be payable to the contractor for the asphalt treated permeable material. Once the target asphalt content is determined, the asphalt cement content will be accepted in accordance with Subsection 406- 7.04 of the specifications. (
B.Cement Treated Permeable Material: Aggregates shall be clean and free from decomposed materials, organic material, and other deleterious substances. All -natural aggregates shall be thoroughly and uniformly washed before use. TABLE OF CONTENTS INDEX The gradation of the aggregate shall meet the following requirements when tested in accordance with Arizona Test Method 201: Sieve Size Percent Passing 1-1/2 inch 100 1 inch 88 - 100 3/4 inch 50 - 80 3/8 inch 15 - 40 No. 4 0 - 16 No. 8 0 - 6 No. 200 0 - 2.0 Aggregate shall conform to the following additional quality requirements prior to the addition of cement: Tests Test Method Requirement Fractured Coarse Aggregate Particles Arizona Test Method 212 Min. 90% Abrasion AASHTO T 96 500 Rev., Max. 45% Sand Equivalent AASHTO T 176 Min. 55 The combined bulk specific gravity range for the aggregate shall be 2.35 to 2.85. The combined water absorption range for the aggregate shall be zero to 2.5. Aggregates and cement for cement treated permeable material shall be stockpiled, proportioned, and mixed in the same manner provided for in Subsection 1006- 4 of the specifications, except as follows: Dividing of the aggregate into sizes will not be required. The Portland cement content of cement treated permeable material shall be no less than 282 pounds per cubic yard. The water:cement ratio (the ratio of the amount of water, exclusive only of that absorbed by the aggregate, to the amount of cement, by weight) shall be approximately 0.37:1. The exact water:cement ratio shall be as specified or approved by the Engineer.
C.Drainage Geotextile Fabric: The drainage geotextile fabric shall be as specified in Subsection 1014- 9 of the specifications.
D.Miscellaneous Materials: Concrete for splash pads shall conform to the requirements of Class B concrete. TABLE OF CONTENTS INDEX Mortar placed where edge drain outlets and vents connect to drainage pipes and existing drainage inlets shall be composed of Portland cement, fine aggregate, and water proportioned and mixed as specified herein. The proportion of cement to fine aggregate, measured by volume, shall be 1:2, unless otherwise specified. All materials used in the mortar shall conform to the requirements listed in Subsection 1006- 2 of the specifications. The mortar shall contain only enough water to permit placing and packing. Concrete areas in contact with the mortar shall be cleaned of all loose or foreign material that would in any way prevent bond between the mortar and the concrete surfaces and shall be flushed with water and allowed to dry to a surface dry conditio n immediately prior to placing the mortar. The mortar shall completely fill and shall be tightly packed into recesses and holes, on surfaces, under structural members, and at other locations as specified. After placing, all surfaces of mortar shall be cur ed by the water method as provided for in Subsection 1006- 6.01(B) of the specifications for a period not less than three days. All improperly cured or otherwise defective mortar shall be removed and replaced by the contractor at no additional cost to the D epartment. Expansion type pressure plugs for cleanouts shall seat firmly against the lip of the pipe and shall be an expandable plug manufactured from neoprene or commercial quality expandable duct plugs. The expandable plug shall consist of reinforced polypropylene rigid threaded plug with a commercial quality thermoplastic rubber sealing ring. 507- 3 Construction Requirements: 507- 3.01 General: Edge drains, edge drain outlets, vents, cleanouts, treated permeable material, and filter fabric shall be instal led in accordance with the details shown on the plans and as specified herein unless otherwise approved by the Engineer. Prior to excavating trenches in existing paved areas, the outline of the paved areas to be removed shall be cut to a neat line to a minimum depth of 2 inches with a power -driven saw or a wheel type rock cutting excavator. Cuts along the joint between existing asphalt concrete and existing Portland cement concrete pavement will not be required. TABLE OF CONTENTS INDEX 507- 3.02 Weather Limitations: Drainage fabri c placement and edge drain installation shall not be done when weather conditions, in the opinion of the Engineer, are not suitable to allow placement or installation. Exposure of geotextiles to the elements between lay down and cover shall be a maximum of 14 days to minimize damage potential. 507- 3.03 Fabric Placement: Surfaces to receive drainage fabric shall, immediately prior to placing, be free of loose or extraneous material and sharp objects that may damage the fabric during installation. The fabric shall be aligned and placed in a wrinkle- free manner. Successive sheets or rolls of fabric shall be overlapped a minimum of 12 inches in the direction the material is being spread. Should the fabric be damaged during placing, the torn or punctured section shall be either completely replaced or shall be repaired by placing a piece of fabric that is large enough to cover the damaged area and to meet the overlap requirement. Damage to the fabric resulting from the contractor's vehi cles, equipment , or operations shall be replaced or repaired by the contractor at no additional cost to the Department. 507- 3.04 Edge Drain Construction Details: Pipe and fittings shall be joined by solvent cementing. The solvent cement and primer shall be of commercial quality specifically manufactured for use with rigid PVC plastic pipe and fittings. The solvent cement and primer used shall be made by the same manufacturer. The color of the primer shall contrast with the color of the pipe and fittings. The solvent cement and primer shall be used in accordance with the manufacturer's printed instructions. Treated permeable material shall be spread only when the atmospheric temperature is above 40 degrees F and in layers not to exceed 8 inches. When edge drains are to be installed adjacent to an asphalt treated permeable base, the treated permeable material may be spread with the treated permeable base, except for the lower 6 inches of asphalt treated permeable material, which shall be spread in a separat e operation. Asphalt treated permeable material shall be placed at a temperature of not less than 180 degrees F nor more than 230 degrees F. When asphalt treated permeable material is spread with asphalt treated permeable base, the placement shall conform to the temperature requirements for spreading asphalt treated permeable base. Treated permeable material spread with adjacent treated permeable base shall be compacted in the same manner as specified for compacting the base. All other layers of treated permeable material shall be TABLE OF CONTENTS INDEX compacted with a vibrating shoe- type compactor connected to a spreading device. The vibrating shoe- type compactor shall be in operation only when the material is being spread in the trench. Cement treated permeable material which is not covered with asphaltic concrete within 12 hours after compaction of the permeable material shall be cured by either sprinkling the material with a fine spray of water every four hours during daylight hours or covering the material with a white pol yethylene sheet, not less than 6 mils thick. The above curing requirements shall begin at 7:00 a.m. on the morning following compaction of the cement treated permeable material and continue for the next 72 hours or until the material is covered with asphaltic concrete, whichever is less. The cement treated permeable material shall not be sprayed with water during the first 12 hours after compacting, but shall be covered with the polyethylene sheet from the completion of the compaction to the beginning of the cure period. Trenches in the existing embankment areas shall be backfilled with native material and compacted as directed by the Engineer. Aggregate base for backfilling trenches in existing paved areas shall be Class 1, 2, or 3 aggregate base. Aggregate base backfill shall be spread and compacted by methods that will produce a uniform base, firmly compacted, and free from pockets of coarse or fine material. Asphaltic concrete for backfilling trenches in existed paved areas shall be dense graded asphaltic concrete material as approved by the Engineer. Prior to placing the asphaltic concrete backfill, a tack coat of asphaltic emulsion shall be applied to the vertical edges of existing pavement at an approximate rate of 0.05 gallons per square yard. Asphaltic concrete backfill shall be spread and compacted in approximately two equal layers by methods that will produce an asphaltic concrete sur facing of uniform smoothness, texture , and density. Each layer shall be compacted before the temperature of the mixture drops below 250 degrees F. Surplus excavated materials shall become the property of the contractor and shall be disposed of in accordance with the specifications outside the right of way. The locations of outlets, vents, and cleanouts will be marked with soil anchored flexible delineator posts in accordance with the plans and as approved by the Engineer. The edge drain outlet, vent, and cleanout pipes shall be clean at the time of installation and shall be free of obstructions after installation. The contractor shall use a high pressure, flexible hose with a nominal 1-inch diameter nozzle containing flushing and propelling jets. The hose shall be inserted into each edge drain outlet, vent, and cleanout pipe and pushed through the pipe with a minimum 1,000 pounds per square inch water pressure so that the entire edge drain system will be penetrated by the flushing nozzle. Pipes that are f ound to be plugged TABLE OF CONTENTS INDEX shall be replaced by the contractor, including replacement of treated permeable material, surfacing and backfill materials, at no additional cost to the Department. Outlet and vent covers consisting of commercial quality 1/2- inch mesh galvanized metal screens or grates with polyvinyl chloride slip joint nut fittings shall be installed at the end of each outlet pipe and vent pipe. 507- 4 Method of Measurement: The various sizes of edge drains, drain outlets, splash blocks, vents, and cleano uts, as shown on the plans, will be measured by the linear foot along the centerline of the pipe and shall include the length of fittings. Tees, wyes and other branches will be measured as pipe along the central axis of the pipes to the point of intersect ion. Measurement will be made end to end to the nearest foot along the actual length of pipe. The pay length shall not exceed the length staked or ordered by the Engineer. The total linear feet measured of each type and size of underdrain pipe shall be t he sum of the above measured quantities. 507- 5 Basis of Payment: The accepted quantities of each type and size of edge drain measured as provided above, will be paid for at the contract unit price per linear foot, complete in place. The contract price shall be full compensation for furnishing all labor, materials, tools, equipment, and incidentals involved in installing perforated pipe, drainage fabric, and treated permeable material as specified in the plans and specifications, and as directed by the Engi neer. This contract unit price shall also include outlet and vent covers, expansion plugs, flexible markers for future location, concrete splash pads, connecting outlets and vents to drainage facilities, and any necessary excavation and backfill of aggregate base, asphaltic concrete, asphalt emulsion tack coat, and native materials. No deduction in the length of plastic pipe will be made for gaps in edge drain pipe at locations of dual outlet, dual vent, or dual outlet and vent connections to the edge drain. TABLE OF CONTENTS INDEX SECTION 601 SECTION 601 CONCRETE STRUCTURES: 601- 1 Description: The work under this section shall consist of furnishing all materials and constructing structures or parts of structures to the forms, shapes, and dimensions shown on the project plans and to the lines and grades established by the Engineer and in accordance with the requirements of the specifications. When the structures or parts of structures are precast, the work shall also include transporting and erecting the units. Precast/Prestressed concrete structural bridge members such as, but not limited to I -Beams and Box Beams are hereby defined as precast bridge structures. Precast bridge structures shall be constructed per the project plans and the requirements of these specifications. Concrete structures such as manhole, concrete pipe, cattle guards, catch basins, median barriers, headwalls, and other small miscellaneous structures of sizes which can readily be precast as units and furnished and installed in place are hereby defined as minor precast structures. Minor precast structures, at the option of the contractor, may be either constructed of cast -in-place concrete or furnished and installed as precast units providing they are fabricated i n accordance with drawings submitted and approved in accordance with the requirements of the specifications. References to “precast concrete items” shall be understood to include both precast bridge structures and minor precast structures. Minor precast structures shown on the Department’s Approved Products List (APL) may be used as alternatives to cast -in-place minor structures. The current list of such precast structures is available on the internet from the Arizona Department of Transportation Research Center through its product evaluation program. Minor precast structures not appearing on the APL may be considered for use in accordance with the requirements of Subsection 106.14 of the specifications. The "H" dimension for catch basins shall be determined in the field prior to casting. The contractor shall be familiar with conditions peculiar to the project, which might limit the use of precast items. The use of precast cattle guards for either H -10 or H -20 loading shall be limited to roadway locations with maximum longitudinal grades of 6 percent. 601- 2 Materials: 601- 2.01 General: A Certificate of Compliance or a Certificate of Analysis conforming to the requirements of Subsection 106.05 of the specifications shall be TABLE OF CONTENTS INDEX SECTION 601 submitted for all specified and applicable materials subject to shop drawing approval prior to their incorporation into precast concrete items. Materials include, but are not limited to; reinforcing steel, prestressed cable strands, bearing plates, embed materials, inserts, anchor plates, epoxy coated or galvanized materials, and mechanical lifting devices. Materials that fail to have the required certification will not be allowed. A Certificate of Compliance conforming to t he requirements of Subsection 106.05 of the specifications for concrete pipe shall accompany each delivery, and shall include the class or type, quantity, and the approved dates of the concrete pipe delivered. Portland cement concrete shall conform to the requirements of Section 1006 of the specifications for Class S or Class B concrete as shown on the project plans. Whe n the specified concrete strength is shown on the project plans but a class of concrete is not indicated, it shall be construed to mean Class S concrete having the required minimum compressive strength shown at 28 days. Except for tack welding of steel cages for concrete pipe and manholes, all welding for precast concrete items shall be performed by or under the supervision and direction of a welder certified for the type of welding required; however, all structural welding and precast bridge structure welding, such as studs, bear ing plates, etc. shall be performed by a welder certified for the type of welding specified. Reinforcing steel cages welded by automated equipment or by plant personnel shall be tested by the manufacturer quarterly, at random, for strength. When requested, reinforcement weld test results shall be supplied to the Engineer. The manufacturer shall submit welding certifications to the Engineer before welding operations begin. Liquid membrane- forming compound shall conform to the requirements of Subsection 1006 -6.01(C) of the specifications. Materials furnished for expansion joint filler and joint seal shall conform to the requirements of Section 1011 of the specifications. Materials furnished for water stops shall conform to the requirements of Section 1011 of the specifications. Preformed bearing pads and elastomeric bearing pads shall conform to the requirements of Section 1013 of the specifications. Reinforcing steel shall conform to the requirements of Section 1003 of the specifications. TABLE OF CONTENTS INDEX SECTION 601 601- 3 Construc tion Requirements: 601- 3.01 General :
A.Shop Drawings: Shop drawings of the proposed concrete structures shall be submitted in accordance with the requirements of Subsection 105.03 of the specifications. The size, shapes, dimensions, and concrete cover shall be shown for the reinforcing steel, including any reinforcing steel to be relocated or added. In addition to all required working drawings, the contractor shall prepare composite drawings in plan, elevation and section which show to scale the relative positions of all items that are to be embedded in the concrete. Such embedded items include the reinforcing steel, anchor bolts, earthquake restrainers, deck joint assemblies, drainage systems, utility conduits and other such items. Such drawings shall be adequate to ensure that there will be no conflict between the planned positions of any embedded items, and that concrete cover will be adequate. If during the preparation of such drawings conflicts are discovered, the contractor shall revise its working drawing for one or more of the embedded items, or propose changes in the dimensions of the work as necessary to eliminate the conflicts or provide proper cover. Any such revisions shall be approved by the Engineer before work on an effected item is started. The shop drawings reviewer shall notate their full first and last nam e and contact phone number on the approved shop drawings. The contractor shall submit a copy of the approved shop drawings to the Structural Materials Testing Section at least 5 working days in advance of the start of production of the precast items. Any changes to shop drawings must be approved by the Engineer. These updated and approved shop drawings shall be sent to the Structural Materials Testing Section at least 24 hours in advance of the start of production.
B.Scheduling and Inspection of Precas t Items: The contractor shall provide the Engineer written notification a minimum of 10 days prior to start of production. The contractor shall also provide notification for any changes in production or pauses in production of precast items that require detailed inspections. The contractor shall schedule a meeting which includes the precast manufacturer’s QC Manager and Production Manager, the Engineer, and Structural Materials Testing Section personnel to discuss scheduling and potential issues regarding the precast items to be manufactured. The meeting shall be held no less than 7 days prior to the start of production. TABLE OF CONTENTS INDEX SECTION 601 The contractor shall provide the Engineer on the Friday before any subsequent week of production a written schedule for the upcoming seven days which includes the following:
1.Date and time for the start of production;
2.Scheduled times for tensioning (if applicable) ;
3.Scheduled times for steel inspection;
4.Pour schedule including product ID or marked number for casting ; and
5.Scheduled times for concrete release breaks. The contractor shall provide a written notice to the Engineer a minimum of 10 days prior to delivery of precast items in order for the Structural Materials Testing Section to schedule and perform a final inspection. 601- 3.02 Falsework and Forms:
A.Design and Drawings: The contractor shall be responsible for designing and constructing safe and adequate falsework and forms which provide the necessary rigidity, support the loads imposed, and produce in the finished structure the lines, grades, and dimensions shown on the proj ect plans and established by the Engineer. The contractor shall apply the best practice principles available from the current publications of AASHTO’s Guide Design Specifications for Bridge Temporary Works and Construction Handbook for Bridge Temporary Wor ks. Forms shall be any system of structural elements which provide horizontal support or restraint to the lateral pressure of concrete. Falsework shall be any system of structural elements that provide temporary lateral and vertical support for loads from plastic concrete, forms, reinforcing steel, structural steel, loads from placement operations or other related loads, and continues to provide support until the concrete has attained adequate strength and the structure is capable of self -support. Stay -in-place metal forms for cast -in-place concrete decks are also considered a falsework system. The design load for falsework shall consist of the sum of dead and live vertical loads, and an assumed horizontal load. The minimum total vertical design load for any falsework shall be not less than 100 pounds per square foot for the combined live and dead load, applied over the area supported, regardless of concrete slab thickness. TABLE OF CONTENTS INDEX SECTION 601 Dead loads shall include the weight of concrete, reinforcing steel, forms, and falsework. The weight of concrete, reinforcing steel and forms shall be assumed to be not less than 160 pounds per cubic foot for normal concrete and not less than 130 pounds per cubic foot for lightweight concrete. Live loads shall consist of the actual weight of any equipment to be supported by falsework applied as concentrated loads at the points of contact and a uniform load of not less than 50 pounds per square foot applied over the area supported. The assumed horizontal load to be resisted by th e falsework bracing system shall be the sum of the actual horizontal loads due to equipment, construction sequence or other causes and an allowance for wind, but in no case shall the assumed horizontal load to be resisted in any direction be less than 2 percent of the total dead load. The falsework shall be designed so that it has sufficient rigidity to resist the assumed horizontal load without considering the weight of the concrete. If the concrete is to be prestressed, the falsework shall be designed to support any increased or readjusted loads caused by prestressing forces. Falsework shall be designed by the working stress design method, and stresses under all loads shall not exceed the maximum allowable stresses provided for in the current edition of AASHTO Guide Design Specifications for Bridge Temporary Works. The maximum allowable stresses provided for in the current National Design Specification (NDS) for wood construction may be used as an alternate to the AASHTO specifications for timber design. The maximum allowable horizontal shear stress in timber shall not exceed 125 pounds per square inch after all applicable modification factors have been applied. No increase in allowable stresses for repetitive member uses will be allowed. Unless otherwise specified on the plans, deflection of the falsework span due to the weight of concrete only shall not exceed 1/240 of the falsework beam span irrespective of the fact that the deflection may be compensated for by camber strips. In the case of post -tensioned structures, the falsework deflections shall not produce stresses in the structure at any time prior to post -tensioning greater than 0.8 times the modulus of rupture for plain concrete unless approved by the Engineer. Falsework over or adjacent to roadways or railroads which are open to traffic shall be designed and constructed so that the falsework is stable if subjected to impact by vehicles. Falsework posts which support members that cross over a roadway or r ailroad shall be considered as adjacent to roadways or railroads. Other falsework posts shall be considered as adjacent to roadways or railroads only if they are located in the row of falsework posts nearest to the roadway or railroad and the horizontal distance from the traffic side of the falsework to the edge of TABLE OF CONTENTS INDEX SECTION 601 pavement or to a point 10 feet from the centerline of track is less than the total height of the falsework and forms. The vertical load used for the design of falsework posts and towers, but not footings, which support the portion of the falsework over openings, shall be increased to not less than 150 percent of the design load calculated in accordance with the provisions for design load previously specified. Falsework posts adjacent to roadways or railroads shall consist of either steel with a minimum section modulus about each axis of 9.5 inches cubed or sound timbers with a minimum section modulus about each axis of 250 inches cubed. Each falsework post adjacent to roadways or railroads shall be mechanically connected to its supporting footing at its base, or otherwise laterally restrained, so as to withstand a force of not less than 2,000 pounds applied at the base of the post in any direction except toward the roadway or railroad track. Such posts also shall be mechanically connected to the falsework cap or stringer. Such mechanical connection shall be capable of resisting a load in any horizontal direction of not less than 1,000 pounds. For falsework spans over roadways, all exterior falsework stringers, stringers adjacent to the ends of discontinuous caps, the stringer or stringers over points of minimum vertical clearance, and every fifth remaining stringer, shall be mechanically connected to the falsework cap or framing. Such mechani cal connections shall be capable of resisting a load in any direction, including uplift on the stringer, of not less than 500 pounds. Such connections shall be installed before traffic is allowed to pass beneath the span. For falsework spans over railroa ds, all falsework stringers shall be so connected to caps. The falsework shall be located so that falsework footings or piles are at least 3 inches clear of railing posts and barriers a nd all other falsework members are at least 1 foot clear of railing members and barriers. Falsework bents within 20 feet of the center line of a railroad track shall be sheathed solid in the area between 3 and 17 feet above the track elevation on the side facing the track. Sheathing shall consist of plywood not less than 5/8 inch thick or lumber not less than 1 inch thick (nominal). Bracing on such bents shall be adequate so that the bent resist s the required assumed horizontal force or 5,000 pounds, whichever is greater. Drawings shall be prepared in accordance with the requirements of Subsection 105.03 of the specifications. The drawings shall be complete and show the dimensions and material for all parts, arrangement, spacing, and connections, and all provisions for adjustment and for measuring displacement. The falsework TABLE OF CONTENTS INDEX SECTION 601 foundations, any connections or contacts with previously built structures or other w orks, and the means of protecting such other works from damage shall be detailed. The above data may be presented either on the drawings or in the design summary, which shall also describe the assumptions and types of calculations used in the design and the stresses and deflections found for critical points. For soffit fill construction, the equivalent of the above drawings and data shall be submitted, and in addition the source, classification, and compaction requirements for the material and the results of any tests performed on the material. In no case shall the soffit fil l be compacted to less than 90 percent compaction, and the top 3 feet shall be compacted to a minimum of 95 percent compaction when tested in accordance with the requirements of the applicable test methods of the ADOT Materials Testing Manual, as dir ected and approved by the Engineer. The soffit fill shall be topped with a lean concrete waste slab screeded to the required grades. Falsework design requires written approval by the Engineer prior to commencing work and shall be in accord ance with the requirements of Subsection 105.03 of the specifications. Falsework calculations shall be sealed and signed by a professional engineer who is registered as a Civil or Structural Engineer in the State of Arizona. In the application and design of deck falsework systems, all bridge girders, new or existing, shall be braced or tied to resist any forces that would cause rotation and torsion in the girders caused by the placing of concrete for diaphragms or decks. In lieu of this requirement, the contractor’s professional engineer shall provide sealed calculations to prove the bridge girders are adequate to resist those effects. Except as provided for on the project plans, supports for deck falsework, forming or screed supports shall not be welded to steel girders, shear connectors, slab ties, or girder stirrups. Modifications of girders to support falsework and forming will not be allowed except as approved by the Engineer. This includes connections of any type in girder webs and flanges to support deck forming. Through- holes of any type in girder flanges will not be permitt ed. When modification of girders to support the deck falsework and forming has been approved by the Engineer, shop drawings for both the girders and the falsework and forming shall be submitted concurrently so that the review and approval of the drawings can be coordinated. The tops of the erected girders shall be surveyed by the contractor in the field prior to placement of the deck forming falsework. The survey shall include girder ends, tenth points, station and offset of survey point locations, or as specified in the project plans. This survey shall be submitted to the Engineer for evaluation. If the top of erected girder elevations are higher than the screed elevations minus the combined deck slab and the buildup thicknesses, adjustments may have to be made in the roadway profile, screed elevations, or girder bearing seat TABLE OF CONTENTS INDEX SECTION 601 elevations. Encroachment into the deck slab of up to 1/2 inch will be allowed for random occurrences.
B.Falsework Construction:
1.General Requirements: The falsework shall be constructed to conform to the falsework drawings. The materials used in the falsework construction shall be of the quality necessary to sustain the stresses required by the falsework design. The workmanship used in falsework construction shall be of such quality that the falsework support s the loads imposed. The contractor shall provide temporary bracing for the falsework system to withstand all imposed loads during erection and removal of any falsework. Wind loads must be included in the design of the temporary bracing. Falsework shall be founded on a solid footing safe against undermining and capable of supporting the loads imposed. Wedges, screws, or jacks shall be used in connection with falsework to set the forms to required grade and uniform bearing prior to placing concrete. All wedges shall be in pair s to ensure uniform bearing. Laminated sections will not be permitted. If additional material is required under wedges, either single blocks or thicker wedges will be required. A sufficient number of wedges shall be used to cover the entire bearing area. The contractor shall provide tell -tales attached to the soffit forms and readable from the ground in enough systematically placed locations to determine the total settlement of the entire portion of the structure where concrete is placed. If any signs of distress develop during the placing of the concrete or the falsework shows any undue settlement or distortion, the work shall be stopped and the falsework corrected and strengthened.
2.Submittals: The contractor shall submit to the Engineer the methods and sequences of falsework construction, including all equipment the contractor plans on using to erect the falsework, and shall certify that the material used to construct the falsework meets the requirements of Subsection 601- 3.02(B)(1) of the specifications. If the contractor elects to deviate from the superstructure placing diagram shown on the design plans, the contractor shall submit a TABLE OF CONTENTS INDEX SECTION 601 superstructure placing diagram showing concrete placing sequence and construction joint locations per the requirements of Subsection 601- 3.03(B) of the specifications. No concrete shall be placed in any forms supported by falsework until the contractor’s Professional E ngineer or their designee has inspected the completed falsework, and the contractor’s P rofessional Engineer has issued a properly sealed and signed certificate that the falsework has been constructed according to the approved falsework drawings.
3.Material: When timber members are used to brace falsework bents which are located adjacent to roadways or railroads, all connections for such timber bracing shall be of the bolted type using 5/8 inch diameter or larger bolts, or shall be connected in a manner that equal s 100 percent capacity of the smaller member connected.
4.Welding: All field welds must be performed by an AWS certified welder. The contractor shall submit copies of current AWS certification for all welders to the Engineer before any field welding begins. Field welding and inspection of field welding must comply with the requirements of the most recent edition of the ANSI/AWS Structural Welding Code - Steel.
C.Forms Construction:
1.General Requirements: Forms shall be of wood, metal , or other suitable material conforming to the requirements specified herein. Forming plans for cast -in-place bridge girders shall be prepared in accordance with the requirements of Subsection 105.03 of the specifications. The forms shall be mortar tight and shall be designed, constructed, braced and maintained so that the finished concrete is true to line and elevation and conform s to the required dimensions and contours. Forms shall be designed to withstand the pressure of concrete with consideration given to rate of concrete placement, temperature of the concrete, use of set -retarding admixtures or pozzolanic materials in the concrete, the effects of vibration as the concrete is being placed, and all loads incidental to the construction operations, without distortion, or displacement. Stay -in-place forming shall not be used unless specified on the plans or approved by the Engineer. Expanded metal mesh may be used to form construction joints provided 3 inch cover is maintained. The use of expanded metal mesh in bridge decks is prohibited. TABLE OF CONTENTS INDEX SECTION 601 Forms to be reused shall be maintained at all times in good condition as to accuracy of shape, strength, rigidity, mortar -tightness, and smoothness of surface. Forms or form lumber unsatisfactory in any respect shall not be used. Forms shall be constructed so that portions may be removed without disturbing forms that are to remain. Forms to be used when a Class II finish or ornamental work is required shall be constructed of metal, fiberglass coated panels, or plywood. All form joints shall be taped or caulked. Forms for this work shall be equivalent to first class pattern work. Forms shall be filleted 3/4 inch at all exposed, sharp corners of the concrete, unless otherwise noted in the plans. All forms shall be treated with an approved form release agent before concrete is placed. Any material which would adhere to or discolor the concrete shall not be used. Forms shall be cleaned of all dirt, sawdust, water , and other foreign material prior to placing concrete in the forms. For narrow walls and columns where the bottom of the form is inaccessible, provisions shall be made for cleaning out extraneous material immediately before placing the concrete. The cells of box girders shall be cleared of all loose materials prior to the completion of deck forming when such forming is to remain in place. When the deck forming is to be removed, the cells of the box girders shall be cleared of all loose materials after removal of the forms.
2.Wood Forms: All lumber used for forms shall be free from defects affecting the accuracy of shape, strength, rigidity, mortar -tightness, and smoothness of the surface. All lumber for forms above stream bed s shall be plywood. All form lumber shall be securely fastened to the studding so that cupping cannot occur. Chamfer strips shall be of selected material dressed to true line and uniform dimensions. The interior surfaces of all forms in contact wit h concrete surfaces in the finished work shall be smooth and even. No uneven or offset joints or single boards projecting so that their impressions are left in the concrete will be allowed. Forms, as far as practicable, shall be so constructed that the form marks conform to the general lines of the structure. In general, grain of the lumber and direction of side joints shall be horizontal on wide faces and walls and vertical on narrow faces. If varying widths of panels are used, the wider panels shall be placed on the bottom and the narrower panels near the top. Panel end joints shall be staggered not less than 3 feet. Spreaders made of wood shall not be left in the concrete. TABLE OF CONTENTS INDEX SECTION 601
3.Metal, Fiberglass, and Other Forms: The same provisions as specified under wood forms shall apply to metal and fiberglass forms and in addition, the following shall apply:
a.All bolts and rivet heads shall be countersunk. Clamps, rods, pins, or other connecting devices shall be designed to hold the forms rigidly together and allow removal without injury to the concrete. Forms which do not present a smooth surface or are not properly aligned shall not be used;
b.Care shall be exercised to keep the forms free of dust, grease, or other foreign matter which discolor s the concrete;
c.Metal forms shall be used for the casting of precast I-beams, box beams, and voided or flat slabs where the contract number of units combined dictates production runs equal to or longer than the precasting bed length. A limited number of units, having a total combined length at least one unit length less than bed length, may be cast with alternate forms, as approved by the Engineer. Dimensional tolerances using alternate forms shall conform to the requirements of Subsection 601- 4.02(B) of the specifications; and
d.Waste slabs used as a part of the forms shall be finished to the appropriate grade including any camber. The finished slab shall not vary more than 1/4 inch from the theoretical grade nor more than 1/4 inch from a 10 foot straight edge in any direction.
4.Internal Cells: Internal cells or voids in pre- cast box beams shall be constructed with either wood forms conforming to Subsection 601-3.02(C)(2) of the specifications, or with solid expanded polystyrene. When solid expanded polystyr ene is used, the entire top surface of the polystyrene of the internal void shall be covered with 3/8- inch thick, exterior -grade plywood. Butt joints of the plywood sections shall be at least 2 feet away from any joined section of polystyrene. Polystyre ne sections shall be securely held together by an adhesive recommended by the manufacturer of the polystyrene. All wood forms or polystyrene/plywood sections shall be securely held in place by nails, waterproof adhesive, or other means approved by the Engineer. Internal cells shall be completely sealed so no plastic concrete is allowed to enter the formed cell. TABLE OF CONTENTS INDEX SECTION 601
D.Removal of Falsework and Forms:
1.General Requirements: No falsework or forms shall be relieved of load and no forms shall be removed without approval of the Engineer. Falsework, excluding bridge deck cantilevered overhangs for cast -in- place prestressed structures, shall not be removed until after the prestressing steel has been tensioned and a minimum of 72 hours after the prestressing steel has been grouted. Falsework for the cantilevered bridge deck overhang shall be removed prior to prestressing but shall not be removed within seven days of concrete placement unless the concrete has attained a minimum compressive strength of 3,000 pounds per square inch. In no case shall falsework be removed within five days of concrete placement. On bridges with both transverse and longitudinal stressing, the deck or overhang falsework shall not be removed until after the transverse prestressing has been completed unless shown otherwise on the plans. The deck overhang falsework shall then be removed prior to performing the longitudinal prestressing. Falsework for cast -in-place non- prestressed structures or composite superstructures, excluding concrete above the bridge deck, shall not be removed until either:
a.At least 10 days after the last concrete has been placed in each continuous span and until the compressive strength of all placed concrete has attained at least 70 percent of the required 28- day compressive strength; or
b.At least five days after the last concrete has been placed in each continuous span and until the concrete has attained the required 28- day compressive strength. The sloped exterior girders of cast -in-place box girder bridges shall be laterally braced or supported until the top slab (deck) concrete has been placed and has attained at least 70 percent of the required 28- day compressive strength. Side forms for footings, beams, girders, box culverts, columns, railings, curbs, or other members wherein the forms do not resist dead load bending may be removed after the concrete has set, and the contractor shall cure and protect the concr ete thus exposed in accordance with the requirements of Section 1006 of the specifications. The contractor shall assume all risks and responsibility resulting from such removals. Forms for cast -in-place concrete, unless otherwise specified herein, shall not be removed until at least seven days after concrete has been placed in the forms, without the approval of the Engineer. TABLE OF CONTENTS INDEX SECTION 601 Placement of backfill material shall be in accordance with Subsection 203-5.03(B) of the specifications. Where backfill is to be placed against both sides of a structural element, the backfill elevations on one side of the element shall not exceed the backfill elevations on the opposite side of the element by more than 5 feet. Forms for precast concrete shall stay in place a minimum of eight hours. The period of time between the placement of concrete in the top slab of a standard concrete box culvert (12 foot span or less) and the removal of the slab support forms may be reduced to 48 hours if the top slab remains supported al ong the center line of the culvert span by a continuous beam and line of posts erected as a part of the original slab form, and which remain s in place, undisturbed, a minimum of seven days. If the Engineer allows the removal of forms before the specif ied curing period has elapsed, the contractor shall cure the concrete for the remaining required curing time by one of the methods specified in Section 1006 of the specifications. Forms for cast -in-place concrete above the bridge decks that require a Class II finish may be removed after the concrete has set, providing the required surface finishing of the concrete is completed within four days. If finishing cannot be completed within four days, the forms shall remain in place for seven days. All forms shal l be removed, except forms used to support the deck of box girders when no permanent access to the cells is available. Care shall be taken in removing falsework and forms so as not to deface or damage the structure. Methods of removal likely to damage or cause overstressing of the concrete shall not be used. All falsework shall be removed from under bridge superstructures prior to opening the structure to traffic. Falsework shall be removed in such a manner that excessive stresses are not induced into the structure. Holes shall not be drilled into the structure to facilitate removal of the falsework. Round blockouts may be used for such purpose providing the contractor can submit evidence that the blockouts are not detrimental to the structure and the Engineer approves the use of the blockouts. The maximum blockout diameter shall not exceed 6 inches.
2.Submittals: The contractor shall submit to the Engineer, prior to a pre- activity meeting, the methods and sequences of falsework removal, including all equipment the contractor plans to use in removing the falsework. The falsework removal sequence shall consider load transfer when portions of the falsework have been removed, and the load is being carried by still in -place falsework. The falsework removal plan shall be reviewed TABLE OF CONTENTS INDEX SECTION 601 and approved by a qualified person selected by the contractor before submission to the Engineer. A qualified person, as defined by OSHA, is one who by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated their ability to solve or resolve problems relating to the subject matter, the work, or the project. The contractor shall submit documentation of that person’s status as the qualified person to the Engineer. No falsework removal shall take place until the contractor’s approved falsework removal plan has been reviewed and approved by the Engineer. The falsework removal plan shall include a hazard assessment, shall identify the contractor’s safety superintendent, and shall include plans to secure the area underneath the falsework and adjacent areas, including work zones and roadways that are within t he potential fall zone of any equipment or falsework components while removal operations take place. No personnel shall be permitted under the falsework suspended by a hoisting system, unless the falsework components are secured by an additional temporary load support system. The contractor’s safety superintendent will be responsible for the safety of all personnel allowed into the area beneath and adjacent to falsework during falsework removal activities. A pre -activity meeting shall occur prior to any falsework removal. During the pre -activity meeting, the contractor shall provide the Engineer any necessary changes to the falsework removal plan, the area needed for falsework removal, and any impact the falsework removal has on public safety, project schedule, traffic, and project activities not related to falsework removal. 601- 3.03 Placing Concrete:
A.General Requirements: No concrete shall be plac ed until the placement of reinforcing steel and the adequacy of the forms and falsework have been approved by the Engineer. Adequate time shall be given to the Engineer to check all form dimensions, embedded items, and placement of reinfor cing steel. Concrete shall not be placed until all necessary corrections have been made and all work required for the proposed pour has been completed. Reinforcing steel shall be placed in accordance wit h the requirements of Section 605 of the specifications and the plans. The sequence of concrete placement shall be as shown on the project plans or as approved by the Engineer when not shown on the project plans. TABLE OF CONTENTS INDEX SECTION 601 Concrete shall be placed and consolidated by methods that do not cause harmful segregation and result in a dense homogeneous concrete free of honeycomb or voids. Concrete shall be placed in horizontal layers not more than 24 inches in depth unless otherwise approved by the Engineer. Concrete shall be placed as nearly as possible in its final position and the use of vibrators for shifting the mass of fresh concrete will not be permitted. Dropping the concrete more than 8 feet without the use of approved pipes or tubes will not be allowed. Care shall be taken to fill all areas within the forms and to force the concrete under and around the reinforcement without displacing the reinforcement or other embedded items. Conveying equipment shall be capable of providing a supply of concrete to the point of placement without segregation, or interruptions sufficient to permit loss of plasticity between successive increments. Concrete placed in slabs and floors other than bridge decks shall be struck off by means of a screed. The screed may be self -propelled screed equipment or the type specified under Subsection 401-3.04(D) of the specifications. No concrete that has partially hardened or been contaminated by foreign materials shall be deposited in the structure. The rate of concrete pl acement and consolidation shall be such that the formation of cold joints within monolithic sections of any structure does not occur. Any portion of any structure displaying apparent cold joints will be rejected, unless the contractor, at no additional cost to the Department, can submit evidence that indicates that either a cold joint does not exist or that a cold joint is not detrimental to the structure. The Engineer shall be the sole judge in determining the existence of a cold joint and whet her its existence is detrimental to the structure. The rate of concrete placement for major structures shall not be less than 35 cubic yards per hour unless otherwise specified or approved in writing by the Engineer. This rate shall not apply to precast concrete item s. The rate of concrete placement for the bottom slabs and girder walls of cast -in-place box girder superstructures shall not be less than 60 cubic yards per hour when the volume of concrete to be placed exceeds 300 cubic yards. A post -pour inspection report with at least the following information shall be submitted to the Engineer within 7 days after the production of minor precast structures. The post -pour inspection reports shall include: TABLE OF CONTENTS INDEX SECTION 601
1.Type of product ;
2.Product mark or type ID ;
3.Date of casting ;
4.Mix design;
5.Concrete strength(s) ;
6.Lengths, widths, and heights;
7.Reinforcing steel size;
8.Reinforcing steel placement ;
9.Insert and embed locations;
10.Lifting device locations; and
11.Damage requiring a repair procedure submittal In addition to the above information, the production of precast bridge structures post -pour inspection reports shall include:
12.Projected strand locations;
13.Camber ;
14.Sweeps; and
15.Patched hold -down holes
B.Bridge Deck: The placing of concrete is not permitted until the Engineer is satisfied that the rate of producing and placing concrete shall be sufficient to complete the proposed pour and finishing operations within the scheduled time, that experienced concrete finishers are available to finish the deck and that all necessary finishing tools and equipment are on hand at the site of the work and are in satisfactory condition for use. Concrete shall be placed for the full width of the panel to be poured. After the concrete has been placed it shall be consolidated and then struck off by means of self -propelled screed equipment. Screed equipment shall be designed to operate as close as practicable to bridge curbs or other obstructions. Screed equipment shall travel on steel rails. Rails shall be substantially supported by adjustable steel supports of adequate size securely fastened in place and spaced at sufficiently close intervals to prevent any appreciable deflection in the rails. S teel supports shall be of such types and installed in such manner that when the rail and adjustable support have been removed, there are no voids in the concrete. The steel rails for placing and finishing equipment shall be set to the correct elevat ion shown on the project plans or as established by the Engineer. The rails shall extend beyond both ends of the scheduled length for placement a sufficient distance that permit s the screed and finishing equipment to reach all areas of the concrete placed. Placement of the deck concrete shall be in accordance with the placing sequence shown on the project plans. The contractor shall submit TABLE OF CONTENTS INDEX SECTION 6 01 drawing s showing the placement sequence, construction joint locations, directions of the concrete placement , and any other pertinent data to the Engineer for review. The drawing shall be submitted at least four weeks prior to the date of deck placement. Screed beams or rollers shall be made of metal, or the bottom of the beam shall be metal clad. Roller screeds shall be constructed so that there is no sag or deflection in the screeds. Screed assemblies shall be equipped with vibrators. The screed assemblies shall be so designed that the vibrating units do not contact any reinforcing steel. Vibration shal l be transmitted to the concrete in such a manner that when the motion of the machine is stopped, all vibration cease s. A slight excess of concrete shall be maintained in front of the screed at all times during the screeding operation. The screed shall make as many passes over the slab as may be necessary to obtain a uniform surface. The contractor shall furnish a minimum of two transverse work bridges from which floating, straight edging, and curing operations may be accomplished. The work bridges shall be reasonably rigid and free of excessive deflections. The self -propelled mechanical bridge used for texturing the bridge deck may be substituted for one of the required work bridges. The floating operation shall follow the screeding if required. The float shall have a minimum diameter of 3 inches and have a minimum length of 12 feet. The float shall be constructed so that the surface is maintained true at all times. Prior to placing concrete, the screed shall be traversed the length of the proposed pour and the clearance from the screed to the reinforcing steel and deck thickness shall be checked. The method of determining the clearance shall be approved by the Engineer prior to making such checks. The clearance shall be as indicated on the project plans with a permissible variation of ± 1/4 inch. Deflection of the screed rails as a result of the weight of the screed equipment will not be permitted. All corrections necessary as a result of this operation shall be performed prior to beginni ng the pour.
C.Pumping Concrete: Where concrete is conveyed and placed by mechanically applied pressure, the equipment shall be of suitable type and shall have adequate capacity for the work. The concrete shall not flow either over or through any piping, fittings, or equipment which is fabricated of aluminum or aluminum alloys. The operation of the pump shall be such that a continuous stream of concrete without air pockets is produced. Excessive segregation due to high velocity discharge of the concrete will not be permitted. When pumping is completed, the concrete remaining TABLE OF CONTENTS INDEX SECTION 601 in the pipeline, if it is to be used, shall be ejected in such a manner that there is no contamination of the concrete or segregation of the ingredients. Standby equipment shall be readily available to replace initial pumping equipment should breakdown occur. Where freeze- thaw durability is of concern (such as in bridge decks, overlays, approach slabs, and barrier walls), the concrete shall b e sampled at the supply truck and the point of placement to determine air loss through the pump. If the loss of air, as measured between the supply truck and the point of placement, exceeds 2 percent, the contractor shall employ measures acceptable to the Engineer to reduce the loss of air to less than 2 percent. Sampling and testing shall be performed in accordance with Subsection 1006- 7.02 of the specifications.
D.Vibrating Concrete: All concrete in structures shall be consolidated by means of approved vibrators together with any other equipment necessary to perform the work as specified herein. The minimum frequency of the internal vibrators shall be 8,000 vibration cycles per minute . Vibration shall be applied in the area of the freshly deposited concrete. Vibrators shall penetrate to the bottom of the concrete layer and at least 6 inches into the preceding layer. The vibration shall be of sufficient duration and intensity to consolidate the concrete thoroughly within 15 minutes after it has been deposited in the forms. Vibration shall not be continued at any one point to the extent that localized areas of grout are formed. Application of vibrators shall be at points uniformly spaced and not farther apart than twice the radius over which the vibration is visibly effective. Re-vibration of concrete may be required at any time as directed by the Engineer. The contractor shall provide sufficient equipment to ensure uninterrupted and co ntinuous vibration of concrete.
E.Placing Concrete in Water (Tremie Concrete): Tremie concrete shall be deposited in water only if either specified on the project plans or when directed and then only under the Engineer's supervision. When depositing in water is allowed, the concrete shall be carefully placed in a compact mass in the space in which it is to remain by means of a tremie, bottom dump bucket , or other approved m ethod that does not permit the concrete to fall through the water without adequate protection. The concrete shall not be disturbed after being deposited. No concrete shall be placed in running water and forms which are not reasonably watertight shall not be used for holding concrete deposited under water. TABLE OF CONTENTS INDEX SECTION 601 A head of concrete shall remain above the discharge end of the tremie tube at all times.
F.Bridge Deck Widening and Phased Constructi on: Where the roadway portion of a bridge deck widening or a deck phased construction section is more than 12 feet in width, concrete shall be placed in the roadway portion in accordance with the requirements of Subsection 601-3.03(B) of the specifications . Where the roadway portion of a bridge deck widening or a deck phased construction section is 12 feet or less in width, the spreading and floating of concrete in the roadway portion shall conform to the requirements of Subsection 401- 3.04(D) of the specifications.
G.Pedestrian Rail and Fence: This work shall consist of furnishing and constructing Combination Pedestrian- Traffic Bridge Railing, Pedestrian Fence for Bridge Railing, and Two- Tube Bridge Rail, including all hardware and materials, in accordance with the requirements of the project plans.
H.Bridge Barriers and Transitions: This work shall consist of furnishing and constructing Bridge Concrete Barrier and Transition, including all hardware and materials, in accordance with t he requirements of the project plans.
I.Approach and Anchor Slabs: This work shall consist of furnishing and constructing reinforced concrete approach and anchor slabs for bridges, including all tools, equipment, labor, and materials. All work shall be in accordance with the details shown on the project plans and the requirements of these specifications. 601- 3.04 Joints in Major Structures:
A.Construction Joints: Construction joints shall be placed in the locations shown on the project plans or as approved by the Engineer. Except under emergency conditions, construction joints shall be planned and located in advance of placing concrete. All construction joints shall be perpendicular to the principal lines of stress and in general located at points of minimum shear and moment. Construction joints shall be constructed in accordance with the details shown on the project plans or as directed by the Engineer. Before new concrete is placed against concr ete which has hardened, forms shall be TABLE OF CONTENTS INDEX SECTION 601 drawn tight against the face of the concrete, wood keys shall be removed and the exposed steel or dowels and the entire surface of the construction joint shall be thoroughly cleaned. Immediately ahead of placing fresh concrete on the construction joint, the old concrete shall be thoroughly saturated with water. After placing of concrete has been completed to the construction joint and before placing fresh concrete, the exposed reinforcing steel and the entire surface of the construction joint shall be thoroughly cleaned of surface laitance, curing compound and other materials foreign to the concrete and clean, coarse aggregate exposed. Surfaces of concrete that have been in place for eight hours or more shall be clean ed by abrasive blast methods. Surfaces of concrete that have been in place for less than eight hours may be cleaned with air and water jets provided that surface laitance and curing compound is removed. After the concrete surfaces have been treated as specified, they shall be cleaned of all dust and abrasive material.
B.Deck Joint Assemblies:
1.Description: This work shall consist of furnishing and installing expansion devices including the seals, anchorage system and hardware in conformity with the project plans and the requirements of these specifications.
2.Materials: Elastomer seals shall be of the Compression Seal or Strip Seal type and shall conform to the requirements of Subsection 1011- 5 of the specifications. Steel shapes and plates shall conform to the requirements of ASTM A572 Grade 50, ASTM A588 Grade 50, ASTM A709 Grade 36 or Grade 50W, or as shown on the plans.
3.Construction Requirements:
a.General: Deck joint assemblies shall consist of elastomer and metal assemblies which are anchored to the concrete at the joint. The seal armor shall be cast in the concrete. The completed assembly shall be in planned position, shall satisfactorily resist the intrusion of foreign material and water and shall provide bump- free passage of traffic. For each size of seal on a project, one piece of the material supplied shall be at least 18 inches longer than required by the project plans. The additional length will be removed by the Engineer and used for TABLE OF CONTENTS INDEX SECTION 601 testing by ADO T Materials Group. Certificates of Compliance conforming to the requirements of Subsection 106.05 of the specifications shall be submitted.
b.Fabrication Fabrication of all metal for deck joint assemblies shall be in accordance with the requirements of Subsection 604- 3.02 of the specifications. The deck joint assemblie s’ fabrication plant shall be certified under the AISC Quality Certification program as a Certified Bridge Manufacturer – Component (CPT) All welding shall be in accordance with the requirements of Subsection 604-3.06 of the specifications. All metal parts of deck joint assemblies shall be galvanized after fabrication in accordance with the requirements of ASTM A123 and A153, unless ASTM A588 or ASTM A709 Grade 50W steel is used. Bolts shall be high strength, conforming to the requirements of ASTM F3125 Grade A325, with a protective coating according to the requirements of ASTM F1136 Grade 3. Metal parts of compression seal assemblies do not require galvanizing, plating, or painting.
c.Shop Drawings: Prior to fabrication, the contractor shall submit shop drawings to the Engineer for approval in accordance with the requirements of Subsection 105.03 of the specifications. The shop drawings shall show complete details of the method of installation to be followed, including a temperature correction chart for adjusting the dimensions of the joint according to the ambient temperature and any additions or rearrangements of the reinforcing steel from that shown on the project plans. Deck joint assemblies for prestressed concrete structures shall be instal led at the narrowest joint opening possible to allow for long term creep.
d.Elastomer Seals: Seals shall conform to the requirements hereinbefore specified.
e.Joint Preparation and Installation: The contractor shall form the joint with a secondary concrete pour. The surface of the existing concrete shall be coated prior to the concrete TABLE OF CONTENTS INDEX SECTION 601 being placed with an approved adhesive specifically formulated for bonding new concrete to old concrete. Joints to be sealed shall be covered or otherwise protected at all times prior to installi ng the elastomer portion of the assembly. The elastomer shall be installed at such time and in such manner that it is not damaged by construction operations. The seal element shall be installed subject to these specifications and the approval of the Engineer. Immediately prior to the installation of the seal element, the metal contact surfaces of the joint armor shall be clean, dry, and free of oil, rust, paint , or foreign material. Any perforation or tearing of the seal element due to installation procedures or construction activities will be cause for rejection of the installed seal element. The contractor shall take due care in the placement of the concrete under and around the joint rails to ensure that proper consolidation is achieved. After placement, the Engineer shall inspect the joint for voids by sounding the angle with a hammer. All voids shall be repaired by the contractor by epoxy injection at no cost to the Department.
C.Water Stops: Water stops of rubber or plastic, shall be placed in accordance with the details shown on the project plans. Where movement at the joint is provided for, the water stops shall be of a type permitting such movement without injury. They shall be spliced, w elded, or soldered, to form continuous watertight joints.
D.Joints in Deck Units: After erection and at the time directed by the Engineer, the longitudinal joints or shear keys shall be thoroughly packed with a pre- packaged non- shrink grout or a sand -cement grout with an expansion agent approved by the Engineer. The contractor shall then transversely connect the deck units with the connection rods, stressing and anchoring them as shown on the project plans. 601- 3.05 Finishing Concrete:
A.General Requirements: The appropriate finish, as specified herein, shall be applied to each surface of all concrete struct ures. All formed surfaces shall require a Class I Finish. Formed surfaces shall be finished immediately after the removal of forms in accordance with the requirements specified herein. If rock pockets or honeycomb are of such an extent and character as to affect the strength of the structure and to endanger the steel reinforcement, the Engineer may declare the TABLE OF CONTENTS INDEX SECTION 601 concrete defective and require the removal and replacement of that portion of the structure affected at the expense of the contractor. Formed surfaces normally in view of vehicular or pedestrian traffic, or not covered by fill material shall present a satisfactory appearance of uniform color and texture commonly achieved by the use of clean, smooth plyw ood forms joined tightly or taped at the joints, preformed metal forms, paper tubing forms, or specially- coated forms. If a satisfactory appearance has not been achieved, either in the formed surface or at the joints, the Engineer will order that the surface be finished in accordance with the requirements for a Class II Finish.
B.Class I Finish: All bolts, wires, snap- ties, and rods shall be clipped and recessed 1 inch below the surface of the concrete. All holes, honeycomb, rock pockets, and other surface imperfections shall be cleaned to sound concrete, thoroughly moistened and carefully patched with mortar. All holes as a result of forming or other methods of construction utilized by the contractor shall be cleaned thoroughly, then comp letely filled with and carefully patched with mortar. Mortar shall be composed of one part cement, two parts of fine sand, water , and an adhesive of a type approved by the Engineer. A portion of the required cement shall be white as required to match the color of the surrounding concrete. Small voids due to entrapped air and water in precast concrete items need not be patched.
C.Class II Finish: The surface shall be patched and pointed as specified herein for Class I finish. When the mortar used i n patching and pointing has set sufficiently, the surface shall be rubbed with cork, wood, or rubber floats, polystyrene, or a mechanical carborundum stone. During the rubbing process a thin mortar, matching the color of su rrounding concrete, may be used to facilitate producing a satisfactory lather. The mortar used to produce lather shall not be used in quantities sufficient to cause a plaster coating to be left on the finished surface. Rubbing shall continue until irregularities are removed and there is no excess material. At the time a light dust appears, the surface shall be brushed or sacked. Brushing or sacking shall be carried in one direction so as to produce a uniform texture and color.
D.Finishing Bridge Deck:
1.General: Bridge decks to be covered with a special riding surface or waterproofing membrane shall be lightly textured with a burlap drag during the plastic concrete state, after the finishing operation and smoothness test, as specified below, and prior to the curing process. Bri dge decks exposed TABLE OF CONTENTS INDEX SECTION 601 directly to traffic shall be grooved or tined as specified in Subsection 601- 3.05(D)(2) of the specifications. The finishing operation shall be completed before the water sheen disappears. The deck surface shall be finished to a smooth f loated surface, free of mortar ridges, hollows, and any other projections. Water shall not be applied to the deck surface at any time during floating or finishing except that a fine fog mist may be applied as approved by the Engineer. Fogging equipment shall be capable of applying water to the concrete in form of a fine fog mist in sufficient quantity to curb the effects of rapid evaporation of mixing water from the concrete. The fine fog mist shall be applied at a distance not to exceed 12 inches from the surface. Application by brushes or any other method that concentrates water will not be permitted. Excess concrete, mortar, or paste produced by the finishing process shall not be discarded into areas of the bridge deck to be covered by sidewalks, media ns, curbs, or parapets, or otherwise incorporated into the work, but shall be removed and disposed of properly. The finished surface of the concrete shall be tested with a 10- foot straightedge placed on the deck surface. For deck surfaces exposed directly to traffic, the surface plane shall not vary by more than 1/8 inch, as measured from the bottom of the straightedge. Deck surfaces to be covered with a special riding surface or waterproofing membrane shall not vary by more than 1/4 inch, as measured fro m the bottom of the straightedge. Deck surface areas tested during the plastic state that do not meet the smoothness criteria specified above shall be corrected immediately, refinished, and retested. All corrected areas shall be textured to match the fini sh of the surrounding deck surface. Should the deck surface require additional corrections or repair after the concrete has cured, as determined by the Engineer, such work shall be in accordance with Subsection 105.04 of the specifications. If the bridge deck corrections require mechanical grinding, all corrected areas shall be re- textured with sawed grooves to match the finish of the surrounding deck surface. After such corrective grinding and re- grooving is completed, the minimum remaining cover over the reinforcing steel shall be not less than 2- 1/4 inches.
2.Grooving and Tining:
a.General Requirements: Unless longitudinal grooving is specified on the plans, the contractor shall texture the bridge deck, approach slab, and anchor slab with transverse grooves. TABLE OF CONTENTS INDEX SECTION 601 Grooves shall be placed with tine brooming while the concrete is still plastic; however, if an item for Bridge Deck Texturing (Sawed Grooves) is included in the bidding schedule, the bridge deck, approach slab, and anchor slab shall be textured with sawed grooves after the concrete has been cured. A uniform textured surface of grooves shall be installed for the entire length of the bridge deck, approach slabs, and anchor slabs, except for those areas occupied by devices installed on the deck. Widened bridge decks shall be finished to match the existing deck surface texture. Bridge sidewalks shall be textured to a light broomed finish during the plastic concrete state.
b.Tine Brooming: Tine broom texturing shall occur after the Engineer has accepted the smoothness of the finished surface, and during the plastic concrete state, but prior to the curing process. The tined grooves shall terminate at 12 inches ± 3 inches from the face of curbs, bridge rails or median dividers along each edge of th e bridge deck surface. Texturing shall be stopped 9 inches to 12 inches from any devices installed on the bridge deck, including scuppers and expansion devices, whether perpendicular to the tined grooves or skewed. The apparatus producing the texture grooves in the plastic concrete shall be mechanically operated from an independent self -propelled bridge. The bridge shall be used for texturing only, and shall be supported on the same steel rails used for the screed equipment. The tine brooming equipment shall be capable of producing grooves which meet the dimensional requirements specified in Subsection 601- 4.01 of the specifications. The timing of the texture operation in the plastic concrete is critical. The texturing shall be completed before the surface is torn or unduly roughened by the texturing operation. Grooves that close following the texturing will not be permitted. Hand tine brooms shall be provided and available at the job site at all times when texturing plastic concrete.
c.Sawed Grooves:
i.General: Sawed groove texturing shall occur after the Engineer has accepted the finished surface, and after the concrete has cured for at least seven TABLE OF CONTENTS INDEX SECTION 601 days, but before the roadway is opened to traffic. Grooving shall occur prior to the application of any concrete sealer if a sealer is specified in the contract documents. A self -propelled texturing machine built for grooving of concrete surfaces shall be used for making the sawed grooves. The saw grooving equipment shall be capable of producing grooves whi ch meet the dimensional requirements specified in Subsection 601- 4.01 of the specifications. Sawed groove texturing shall terminate at 12 inches ± 3 inches from the face of curbs, bridge rails, or median dividers along each edge of the bridge deck surface. Texturing shall be stopped 9 inches to 12 inches from any devices installed on the bridge deck, such as scuppers and expansion devices that are perpendicular to the grooves. For skewed expansion devices on the bridge deck, the direction of the grooves as specified above shall not be altered, and texturing shall terminate no closer than 6 inches nor farther than 4 feet from the joint armor. The maximum gap in texturing, from one side to other of skewed expansion devices, shall not exceed 5 feet. Overlappi ng of grooves by succeeding passes will not be permitted. (ii) Equipment: The self -propelled texturing machine shall have diamond- tipped circular saw blades mounted on a multi -blade arbor, and shall have a depth control device that detects variations in the dec k surface and adjusts the cutting head height to maintain the specified depth of the groove. The texture machine shall also include devices to control alignment. Single blade equipment may be authorized by the Engineer where multi - blade assemblies are not capable of sawing to within 1 foot of obstructions. Flailing or impact type grooving equipment shall not be used. The grooving equipment shall be equipped with vacuum slurry pickup equipment which shall continuously pick up water and sawing dust, and pump the slurry to a collection tank. (iii) Construction: The contractor shall submit a plan detailing the proposed layout of the texturing to the Engineer for approval at least seven days prior to the grooving operations. Spacing dimensions at the starting and ending point of each pass shall be noted. A description of the saw cutting equipment shall be included. Prior to grooving operations, the contractor shall provide two gauges, designed for verification of groove depth, to the Engineer for approval. The gauges shall be accompanied by the manufacturer’s instructions for TABLE OF CONTENTS INDEX SECTION 601 their use. During grooving operations the contractor shall check the groove dimensions, under the observation of the Engineer, at random locations. If the minimum groove depth has not been achieved, the grooving operation shall stop and the necessary adjustments shall be made. At the beginning of each work shift, the contractor shall furnish a full complement of saw blades for each texturing machine that are capable of cutting grooves of the specified width, depth, and spacing. If during the work a single grooving blade on a machine becomes incapable of cutting a groove, the contractor shall continue work for the remainder of the work shift. It will not be required to cut the groove omitted resulting from the failed blade. If two or more grooving blades on a machine become incapable of cutting grooves, the contractor shall cease operating the machine until it is repaired. The contractor shall continuously remove all slurry from the equipment throughout the grooving operations with a vacuum pickup, and shall dispose of the slurry at an approved off -site location, and in accordance with applicable laws and ordinances for disposal. All textured areas shall be flushed with clear water as soon as p ossible to remove any slurry material not collected by the vacuum pickup. Flushing shall be continued until all surfaces are clean and accepted by the Engineer. The contractor shall repair all damage to the expansion devices caused by the grooving operati on in a manner satisfactory to the Engineer. If the Engineer determines that the expansion device cannot be repaired in a manner which allow s proper functioning of the system, the contractor shall replace the device at no additional cost to the Department. The replacement shall be a new expansion device equal in all respects to the expansion device being replaced. Damage to any other portion of the bridge deck, or to anything attached or embedded in the bridge deck, that is attributable to the contractor’s operations shall be repaired in a manner satisfactory to the Engineer at no additional cost to the Department. 601- 3.06 Curing Conc rete: Curing cast -in-place concrete and precast concrete items shall be in accordance with the requirements of Subsection 1006- 6 of the specifications. TABLE OF CONTENTS INDEX SECTION 601 601- 3.07 Supporting, Handling, Transporting , and Erecting Precast Concrete Items:
A.Plant Operations :
1.General: Precast bridge structures shall be handled or supported at or near the final bearing points for storage. All Precast concrete items shall meet the designed compressive strength requirements for release prior to initial lift ing from the casting bed. The release strength shall be as shown on the plans. All precast concrete items shall be legibly stenciled with a waterproof paint and include, at a minimum, the following:
a.Manufacturer’s name or logo;
b.Date of production ;
c.Descri ption of the product ; and
d.Mark number All applicable manufacturer stenciling shall be applied at the manufacturer’s plant. All precast concrete items shall not be delivered to the project site without an ADOT stencil. Precast items will not be stenciled by ADOT until it has reached the 28- day compressive strength requirement. No precast concrete items shall be shipped for at least 14 days after concrete placement, and until it meets 28- day compressive strength, unless otherwise approved by the Engineer. Until precast concrete items have been approved, they shall be stored in a manner that allows the inspector full access around each item to perform inspections. When lifting precast concrete items from the production bed, setting in storage, loading for delivery, erecting, or placing at the project, each precast concrete item shall be lifted from the lifting points in a manner that does not cause structural damage to the product(s) due to stresses, torsion, or other forces. Precast concrete items shall be supported during transporting in a manner that allows conformity to the proper bearing points. At all time s, the items shall be handled or supported securely in an upright position. Items that have been damaged in shipment will be rejected at the point of delivery. TABLE OF CONTENTS INDEX SECTION 601 Lifting devices shall not project above the surface of the item after placement unless they are embedded in a subsequent concrete pour, have a minimum concrete cover of 2 inches, and do not interfere with the placement of reinforcing steel or concrete. All repairs shall match the color of the concrete being repaired. Patching materials used shall be free of chlorides and meet or exceed the 28 -day concrete compressive strength requirements shown on the plans. All precast concrete items, wit h the exception of concrete pipe, shall meet the dimensional tolerance requirements of Subsection 601 -4.02(B) of the specifications. Concrete pipe dimensional tolerances shall meet the requirements of Subsection 601- 3.07(A)(4) of the specifications.
2.Precast Bridge Structures Plant Operations: Precast bridge structures shall be stored on suitable supports placed on level, well compacted material with adequate drainage. Bridge structures shall be stored in a manner that prevents sweeps or damage. When requested by the Department, the manufacturer shall re- set any bridge structure that is not level. When precast bridge structures are to be stored for more than 60 days after release strength is achieved, the manufacturer shall coordinate with the contractor to address any potential camber issues. The Engineer shall be given written notification of precautions taken. All minor repairs, such as bottom corner spalls and hold -down holes, shall be made with a “High Strength, Non- Shrink” grout which is listed on the Department’s APL. Prior to patching, hold- down holes shall be cleaned of deleterious materials, grease, oil, and laitance. Cracks at the end of girders shall be pressure injected with an epoxy adhesive. Approved epoxy adhesives are listed on the Department’s APL. All major repairs shall require the submittal of a repair procedure for review and approval. Examples of a major repair are: dimensions deviating from specified tolerances, exposed cable strand, concrete voids, missing inserts or pipes, and required projected strand that has been cut off. The contractor shall notify the Engineer immediately of these or other defects before submitting a repair procedure.
3.Minor Precast Structures Plant Operations: Minor precast structures shall be stored on level, well compacted material with adequate drainage. Minor precast structures shall be stored in a manner that prevents damage. When requested by the Engineer, the manufacturer shall reset any precast concrete items that are not level. TABLE OF CONTENTS INDEX SECTION 601 All minor repairs, such as corner spalls and cracks, shall be made with a “High Strength, Non- Shrink” grout which is listed on the Department’s APL. Prior to patching, the area to be patched shall be cleaned of deleterious materials, grease, oil, and laitance. All major repai rs require the submittal of a repair procedure for review and approval. Examples of a major repair may include concrete voids, missing inserts, and missing embeds. The contractor shall notify the Engineer immediately of these or other defects before subm itting a repair procedure.
4.Precast Concrete Pipe: The dimensional tolerance requirements shall meet the appropriate specifications for the pipe used on the project. Such specifications may include, but are not limited to: AASHTO M 86, M 170, M 206, M 207, and M 242. All gauges used for the determination of “D Load”, three edge bearing load, hydrostatic pressure, and other required testing shall be visible from a distance of at least 10 feet. When D -Load testing is required for the specified pipe, the frequency of D-Load testing shall be at least one test for 100 joints per size and class for delivery. Concrete pipe meeting the specifications shall have a date range to cover the 100 joints of no more than the previous six months. When the quantity of pipe is less than 10 joints, the D -Load test requirement may be waived per the inspector’s discretion. Any pipe that fails to meet the D Load requirement shall require at least two additional tests. If any of the additional tests fail, the pipe will be considered unacceptable for that specific class or D Load requirement. Pipe failing a specific class or D -Load may be downgraded to a lower class provided the pipe meets the lower class specifications. If concrete pipe is downgraded, the pipe shall have the original class or D -Load removed from the pipe and the new class stenciled in its place.
B.Bridge Girder Erection: Girders shall be placed accurately on bearings to avoid creating eccentricities capable of initiating imbalance. Girders with shapes that exceed a height to width ratio of two shall be temporarily braced. The girder width shall be determined from the outside dimension of the bottom flange. The contractor shall secure such girders in position on the structure with temporary lateral bracing t o resist loads as specified in the AASHTO Guide Design Specifications for Bridge Temporary Works. Lateral bracing shall be designed to allow for girder temperature movements. TABLE OF CONTENTS INDEX SECTION 601 The bracing shall be placed prior to the release of the erection equipment from each girder. Prior to erection of any girders, the contractor shall provide a lateral bracing plan, prepared and sealed by a P rofessional Engineer registered in the State of Arizona, for the Engineer’s review. Such bracing plan shall be included with the working drawings specified in Subsection 105.03 of the specifications, and shall include supporting calculations. A girder pre -erection meeting shall be scheduled following the review and prior to erection of any girders. All parties involved in the installation shall be represented, and no girders shall be placed until the plan has been approved. No traffic shall be allowed under each newly erected girder until the girder has been laterally braced. Temporary bracing shall remain in place until after per manent concrete diaphragms are installed at the bents, or the girder is integrated with a permanent feature that restricts the girder’s lateral movement. 601- 3.08 Backfilling: Structure backfill shall be placed in accordance with the requirements of Subsection 203- 5.03(B) of the specifications. 601- 3.09 Vertical Restrainers:
A.Description: The contractor shall furnish and install restrainer units consisting of cables and assemblies and associated materials or components in conformance with the details shown on the project plans, and in accordance with the specifications. Components required for each restrainer unit type will be detailed on the project plans and shall include various combinations of the following: cables, clips, No. 11 rebar, duct tape, expanded polystyrene, hardboard, and incidentals.
B.Materials: Cables shall be 3/4 inch diameter preformed, 6 by 19 wire strand core, or independent wire rope core (IWRC), galvanized ASTM A 603 Class A coating, right regular lay, manufactured of improved plow steel with a minimum breaking strength of 21 tons. Two certified copies of mill test reports of each manufactured lengths of cable used shall be furnished to the Engineer. Free ends of cable restrainer units shall be securely wrapped at each end to prevent separation. TABLE OF CONTENTS INDEX SECTION 601 The cable assemblies shall be shipped as a complete unit. A minimum of one test loop assembly per bridge or one test loop assembly for every 40 cable assemblies, whichever is greater, shall be furnished to the Engineer for testing. The test loop assembly shall be fabricated from the same lot of material, wire rope and fittings or clips as the cable assemblies. The test loop assembly shall be not less than 27 inches or more than 33 inches long when pulled taut. Tempered hardboard shall be 1/8 inch minimum in thickness, unless shown or specified otherwise. Hardboard shall conform to the requirements of ANSI 135.4. Expanded polystyrene shall be a commercially available polystyrene board. Expanded polystyrene shall have a flexural strength of 35 pounds per square inch minimum det ermined in accordance with ASTM C 203, and compressive yield strength between 16 and 40 pounds per square inch, at 5 percent compression. When shown on the plans, surfaces of expanded polystyrene shall be faced with hardboard. Other facing materials may be used provided they furnish equivalent protection. All boards shall be held in place by nails, waterproof adhesive, or other means approved by the Engineer.
C.Construction Requirements: Restrainers shall be installed as indicated on the project plans. The contractor shall provide means of holding the cable assemblies in their planned positions. The contractor shall be responsible for determining the required length of the cable assemblies. 601- 3.10 Foundations: Foundations for structures shall be placed on suitable earth or rock bearing, on a concrete foundation seal, or on piling, as shown on the project plans. Excavation and backfill shall be in accordance with the requirements of Subsection 203- 5 of the specifications. No concrete shall be placed under water or against water -bearing strata, except where a tremie concrete procedure is allowed by the Engineer. 601- 4 Tests on Finished Structures: 601- 4.01 Surface Texture: The grooves for decks exposed directly to traffic shall be rectangular in shape and shall be 1/8 inch ± 1/32 inch deep by 1/8 inch ± 1/32 inch wide. Spacing of the grooves shall be 3/4 inches ± 1/8 inch center to TABLE OF CONTENTS INDEX SECTION 601 center. The textured groove depth will be measured in accordance wi th the requirements of Arizona Test Method 310. 601- 4.02 Dimensional Tolerances:
A.Cast -in-Place Concrete: The maximum allowable tolerances or deviations from dimensions shown on the project plans or the approved shop drawings shall be as shown in the following tables: Table 601 -1 Dimensional Tolerances Cast -In-Place Concrete Component Variation (+) Variation (-) Cross -sectional dimensions of columns, piers, girders 1/4 inch 1/8 inch Thickness of slabs and walls 1/4 inch 1/8 inch Footing cross sections 2 inches 1/2 inch Footing thickness No Limit (1) 1 inch (2) Slabs on subgrade (excluding footing thickness) 1/4 inch 3/4 inch Girder bearing seats deviation from elevation 1/8 inch 1/4 inch Box girder overall depth 1/4 inch 1/8 inch Box girder slab and wall thickness 1/4 inch 1/8 inch Box girder post -tensioning ducts 1/4 inch 1/4 inch Notes:
1.Does not apply to reinforcing steel placement .
2.Allowable deviation of footing thickness if less than specified is 5% of specified thickness up to a maximum 1 inch . Table 601 -2 Variation/Deviation Cast -In-Place Concrete Component Length Allowable Variation Variation from plumb in the lines and surfaces of columns, piers, abutment, and girder walls ≤ 10 feet segment Entire length (Max.) 3/8 inch 1 inch Girder alignment (deviation from straight line parallel to centerline of girder measured between diaphragms) Every 10 feet 1/8 inch Girder bearing seats (deviation from plane surface flatness) Every 10 feet 1/8 inch TABLE OF CONTENTS INDEX SECTION 601
B.Precast Concrete Structures:
1.General: Precast units that do not comply with the dimensional tolerances specified herein will be rejected. Precast units that show evidence of cracks, pop outs, voids, or other evidence of structural inadequacy or imperfections that reduce the aesthetics of the unit after final placement will be rejected.
2.Precast Concrete I -Beams: The maximum allowable tolerances of deviations from dimensions and details shown on the project plans or the approved shop drawings shall be as shown in the following table: Table 601 -3 Dimensional Tolerances Precast Concrete I -Beam Component Varia tion (+) Variation (-) Length 3/4 inch 3/4 inch Width (flanges and fillets) 3/8 inch 1/4 inch Depth (overall) 1/2 inch 1/4 inch Width (web) 3/8 inch 1/4 inch Depth (flanges and fillets) 1/4 inch 1/4 inch Stirrup bars (deviation from top of beam) 1/4 inch 3/4 inch Horizontal position of deflection points for deflected strands (placed symmetrically about the center) 10 inches 10 inches Position of handling devices 6 inches 6 inches Bearing plates (ctr. to end of beam) 1/4 inch 1/4 inch Side inserts (ctr. to ctr. and ctr. to end) 1/2 inch 1/2 inch Bearing area deviation from plane 1/8 inch 1/8 inch Stirrup bars (longitudinal spacing) 1 inch 1 inch Position of post -tensioning duct 1/4 inch 1/4 inch Position of weld plates 1 inch 1 inch Exposed horizontal beam ends (deviation from square or designated skew) 1/4 inch 1/4 inch Exposed vertical beam ends (deviation from square or designated skew) per foot of beam depth 1/8 inch 1/8 inch Horizontal alignment deviation from straight line parallel to center line of member shall not be greater than 1/8 inch per every 10 feet in length. Bearing plates (center to center) deviation shall not exceed ± 1/8 inch per 10 plates, but not greater than ± 3/4 inch. Tendon position deviation from center of gravity of strand group and individual strands shall not be greater than ± 1/4 inch. TABLE OF CONTENTS INDEX SECTION 601
3.Precast Concrete Box Beams and Flat Slabs: The maximum allowable tolerances or deviations from dimensions and details shown on the project plans or the approved shop drawings shall be as shown in the following table: Table 601 -4 Dimensional Tolerances Precast Concrete Box Beams and Flat Slab s Component Variation (+) Variation (-) Length 3/4 inch 3/4 inch Width (overall) 1/4 inch 1/4 inch Depth (overall) 1/4 inch 1/4 inch Width (web) 3/8 inch 3/8 inch Depth (top slab) 1/4 inch 1/4 inch Depth (bottom slab) 1/4 inch 1/8 inch Position of tendons (C.G. of strand group) 1/4 inch 1/4 inch Longitudinal spacing of stirrup bars 1 inch 1 inch Position of handling devices 6 inches 6 inches Square ends (deviation from square) 1/2 inch 1/2 inch Skew ends (deviation from designated skew) 1/2 inch 1/2 inch Beam seat bearing area (variation from plane surface when tested with a straightedge through middle half of member) 1/8 inch 1/8 inch Dowel tubes (spacing between the centers of tubes and from the centers of tubes to the ends and sides of items) 1/2 inch 1/2 inch Tie rod tubes (spacing between the center of tubes and from the centers of tubes to the end of the member) 1/2 inch 1/2 inch Tie rod tubes (spacing from centers of tubes to the bottom of the beams) 3/8 inch 3/8 inch Position of side inserts 1/2 inch 1/2 inch Position of weld plates 1 inch 1 inch Horizontal alignment deviation from straight line parallel to center line of member shall not be greater than 1/8 inch per every 10 feet in length. Camber differential between adjacent units shall not be greater than 3/4 inch. Slab Void position shall not be greater than 1/2 inch from end of void to center tie hole plus an additional inch adjacent to end block. The total width of deck shall be the theoretical width ± 1/2 inch per joint.
4.Precast Minor Structures : The maximum allowable tolerances or deviations from the dimensions shown on the drawings shall be as shown in the following table: TABLE OF CONTENTS INDEX SECTION 601 Table 601 -5 Cross -sectional Dimensional Tolerances Minor Precast Structures Component Variation (+) Variation (-) Sections 6 inches or less 1/8 inch 1/8 inch Sections 18 inches or less and over 6 inches 3/16 inch 3/16 inch Sections 36 inches or less and over 18 inches 1/4 inch 1/4 inch Sections over 36 inches 3/8 inch 3/8 inch The dimensional tolerance for the overall dimensions of a member shall be ± 1/4 inch per 10 feet of length, with a maximum of ± 3/4 inch. Deviations from straight line shall not be more than 1/4 inch per 10 feet of length. All exposed, sharp corners of the concrete shall be filleted 3/4 inch with a maximum allowable deviation of ± 1/8 inch. 601- 4.03 Compressive Strength and Acceptance: Sampling and testing for compressive strength and acceptance for compressive strength will be in accordance with the requirements of this section and Subsection 1006- 7 of the specifications. 601- 4.04 Opening to Traffic: No vehicular traffic will be allowed on the structure until at least 10 days after the last concrete has been placed in each continuous portion of a structure and until the compressive strength of all placed concrete has reached the required 28- day compressive strength on structures in which cast -in-place concrete has been used. No vehicular traffic will be allowed on the structure until after the structure has been prestressed, tendons grouted, and all falsework removed from under the superstructure, for cast -in-place prestressed structures. 601- 5 Method of Measurement: When concrete is to be paid for by the cubic yard, measurement will be made in accordance with the dimensions shown on the plans or such other dimensions as may be ordered in writing by the Engineer. No deduction will be made for the volume occupied by reinforcing steel, structural steel, prestressing materi als, or pile ends embedded in the concrete. The quantity of precast, prestressed structural concrete items shall be measured to the nearest linear foot for each type and size of girder, box beam, or voided slab, as shown on the bidding schedule, installed in place, complete, and accepted. Each member shall include the TABLE OF CONTENTS INDEX SECTION 601 concrete, steel reinforcement , and prestressing steel, enclosures for prestressing steel, anchorages, plates, nuts, elastomeric bearing pads, and such other materials contained within or attached to the unit. Deck joint assemblies will be measured by the linear foot. Measurement will be made along the center line of the joint and at the surface of the roadway or sidewalk from face- of-curb or barrier to face- of-curb or barrier. Measur ement will be to the nearest linear foot. No measurement will be made for that portion of the deck joint assembly required by plan details to extend through the face- of-curb or barrier, such being considered as incidental to the sealing of the joint. Measurement for vertical restrainers will be made for each restrainer acceptably installed in place for each bridge. Combination Pedestrian- Traffic Bridge Railing will be measured to the nearest linear foot from the outside dimensions of the parapet . Pedestrian Fence for Bridge Railing and Two- Tube Bridge Rail will be measured to the nearest linear foot from end- post to end- post. Bridge Concrete Barrier and Transition will be measured to the nearest linear foot. Reinforced Concrete Approach Slab w ill be measured to the nearest square foot. Reinforced Concrete Anchor Slab will be measured to the nearest square foot. No measurement will be made for the reinforced concrete anchor lugs. Bridge Deck Texturing (Sawed Grooves), when included in the bidding schedule, will be measured to the nearest square yard. The area will be determined by the length of the bridge, approach slabs, and anchor slabs, multiplied by the width of the roadway between the face of curb or bridge rail on each side, less 2 feet. The quantity shown on the bidding schedule shall be considered final and will not be re- measured unless changes are specified by the Engineer, or if the Engineer or contractor determines that the constructed area varies by an amount greater or less than 2 percent of the quantity shown on the bidding schedule. Such adjustments, if required, shall be in accordance with Subsection 104.02 of the specifications. 601- 6 Basis of Payment: Class S or Class B concrete, measured as provided above, will be paid for in accordance with the provisions of Subsection 1006 -7.03(B)(2) of the specifications. The contract price paid for Class S or Class B concrete shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals and for doing all work involved in furnishing, placing, and TABLE OF CONTENTS INDEX SECTION 601 curing concrete and transporting and erecting falsework, forms, precast concrete items, water stops, roadway drains, scuppers, metal hinges, and bearing pads to provide a concrete structure complete in place as shown on the project plans, as specified herein, and as directed by the Engineer. The accepted quantities of deck joint assemblies, measured as provided above, will be paid for at the contract unit price per linear foot , complete in place, as shown on the plans. The accepted quantities of Vertical Restrainers, as measured above, will be paid for in accordance with the provisions of Subsection 109.10 of the specifications, Lump Sum Payment for Structures. Payment for minor structures will be made under the various sections of the specifications covering that particular minor structure. The accepted quantities of Combination Pedestrian- Traffic Bridge Railing, Pedestrian Fence for Bridge Railing, and Two- Tube Bridge Rail, measured as provided above, will be paid at the contract unit price, complete in place, including all concrete, reinforcing steel, rail, other materials, and labor. Reinforcing steel embedded below the parapet shall be included in the bridge railing. The accepted quantities of Bridge Concrete Barrier and Transition, measured as provided above, will be paid at the contract unit price, complete in place, including all concrete, reinforcing steel, rail, other materials, and labor. Reinforcing steel embedded below the barrier or transition shall be included in the barrier and transition. The accepted quantities of Reinforced Concrete Approach Slab, measured as provided above, will be paid for at the contract unit price, complete in place, including all concrete, reinforcing steel, l abor, tools, equipment , and incidentals. The accepted quantities of Reinforced Concrete Anchor Slab, measured as provided above, will be paid for at the contract unit price, complete in place, including all concrete, reinforcing steel, labor, tools, equipm ent, and incidentals. No payment will be made for furnishing all materials and constructing reinforced concrete anchor lugs, the cost being considered as included in the contract bid item for the reinforced concrete anchor slab. The accepted quantities of sawed groove texturing, measured as provided above, will be paid for at the contract unit price, complete in place, including all labor, tools, equipment , and incidentals. No measurement or direct payment will be made for texturing of the bridge deck with a burlap drag or by tine brooming, the cost being considered as included in contract items. TABLE OF CONTENTS INDEX
Source: Arizona Standard Specifications for Road and Bridge Construction, 2021 Edition. Pages – of 1,296.