51CONCRETE STRUCTURES

51-1 General

51-1.01 General

51-1.01A Summary

Section 51 -1 includes general specifications for constructing concrete stru ctures. Earthwork for the following concrete structures must comply with section 19 -3:

51-1.01B Definitions

form panel: Continuous section of form facing material, unbroken by joint marks, against which concrete is placed. opening age: Minimum age at which an element constructed with RSC may be opened to traffic. age of break: Age in hours, determined by your testing, at which RSC attains its minimum specified compressive strength. pier column: Extension of a column or pier into bedrock material.

51-1.01C Submittals

51-1.01C(1) General

If ordered, submit concrete form design and materials data for each forming system. Submit a deck placement work plan for concr ete bridge decks. If requested, submit shop drawings for PC members proposed by you. Include construction joint details, foundation bedding, and other requested information.

51-1.01C(2) Permanent Steel Deck Forms

Submit 3 copies of shop drawings for perma nent steel deck forms . Include in the submittal:

51-1.01C(3) Bonding Materials

Except for a bonding material previously authorized by the Department, submit at least a 45 -pound test sample to METS. Allow 45 days for testing. Obtain the Department's autho rization of the bonding material before incorporating it into the work. For a bonding material previously authorized by the Department, submit a certificate of compliance for each shipment of the material.

51-1.01C(4) Rapid Strength Concrete

For RSC , submit the mix design at least 10 days before use. Include in the submittal:

51-1.01C(5) Drill and Bond Dowel —Chemical Adhesive

For each lot or batch of chemical adhesive used for drill and bond dowel chemical -adhesive systems, submit the following:

51-1.01C(6) Colored Concrete

Submit technical data, manufacturer's specifications, and a work plan for mixing, delivery, placement, finishing, and curing of colored concrete.

51-1.01C(7) Hinge Tiedowns

Reserved

51-1.01D Quality Assurance

51-1.01D(1) General

Reserved SECTION 51 CONCRETE STRUCTURES

51-1.01D(2) Quality Control

51-1.01D(2)(a) General

Reserved

51-1.01D(2)(b) Rapid Strength Concrete

51-1.01D(2)(b)(i) General

Reserved

51-1.01D(2)(b)(ii) Prequalification of Mix Design

Prequalify RSC under section 90 -1.01D(5)(b) before use. Prequalification of an RSC mix design includes determining the opening age and attaining the specified minimum 28 -day compressive strength. Determine the opening age of the RSC mix design as follows:

51-1.01D(2)(b)(iii) Mock -ups

Reserved

51-1.01D(2)(c) Test Panels

Test panels must be:

51-1.01D(3) Department Acceptance

51-1.01D(3)(a) General

Reserved

51-1.01D(3)(b) Testing Concrete Surfaces

51-1.01D(3)(b)(i) General

The Engineer tests roadway concrete surfaces for smoothness, coefficient of friction, and crack intensity. The Engineer tests POC concrete deck surfaces for smoothness and crack intensity .

51-1.01D(3)(b)(ii) Surface Smoothness

The Engineer tests the surface smoothness of the following: SECTION 51 CONCRETE STRUCTURES

51-1.01D(3)(b)(iii) C oefficient of Friction

After deck surfaces and approach slabs have been textured, the Engineer performs friction testing of the concrete surfaces under California Test 342. Allow 25 days for the Department to schedule for coefficient of friction testing. Deck surfaces and approach slabs must have a uniform surface texture with a coefficient of friction of not less than 0.35 when opened to traffic or before seal coat s are placed, whichever occurs first. If portions of completed deck surfaces or approach slabs have a coefficient of friction of less than 0.35, those portions must be ground or grooved parallel to the center line to produce a coefficient of friction of not less than 0.35. Grinding and groovin g must comply with section 42. The coefficient of friction requirements do not apply for bridge decks to be covered with membrane seals.

51-1.01D(3)(b)(iv) Crack Intensity

The Engineer measures crack intensity of deck surfaces after curing, before prestressing, and before falsework release. Clean the surface for the Engineer to measure surface crack intensity. In any 500 sq ft portion of a new bridge deck surface, if there are more than 50 feet of cracks having a width at any point of over 0.02 inch, treat the deck with methacrylate resin under section 60 -3.03B. Treat SECTION 51 CONCRETE STRUCTURES the entire deck width between barriers to 5 feet beyond where the furthest continuous crack emanating from the 500 sq ft section is 0.02 inch wide. Treat the deck surface before grinding. In any 100 sq ft portion of a new POC deck surface, if there are more than 10 feet of cracks having a width at any point of over 0.02 inch, treat the deck with methacrylate resin under section 60 -3.03B. Treat the entire de ck width between the curbs to 5 feet beyond where the furthest continuous crack emanating from the 100 sq ft section is 0.02 inch wide. Treat the deck surface before grinding.

51-1.01D(3)(c) Drill and Bond Dowel —Chemical Adhesive

The Department will verif y the chemical adhesive used in the drill and bond dowel chemical adhesive system is chemically consistent with the chemical adhesive material on the Authorized Materials List.

51-1.02 Materials

51-1.02A General

Reserved

51-1.02B Concrete

Except for min or structures, the cementitious material content per cubic yard of concrete in structures or portions of structures must comply with the content shown in the following table : Use Cementitious material content (lb/cu yd) Deck slabs and slab spans of bridges 675–800 Roof sections of exposed top box culverts 675–800 Pier columns 675–800 Seal courses 675 min Other portions of structures 590–800 Concrete for PC members 590–925 Except for minor structures, the minimum required 28 -day compressive strength for concrete in structures or portions of structures is the compressive strength described or 3,600 psi, whichever is greater. Concrete for concrete bridge decks or PCC deck overlays must contain:

51-1.02C Bonding Materials

Bonding materials must be magnesium phosphate concrete , modified high -alumina -based concrete , or portland -cement -based concrete . Magnes ium phosphate concrete must be either single component that is water activated or dual component with prepackaged liquid activator. Modified high -alumina -based concrete and p ortland -cement -based concrete must be water activated. Bonding materials must comply with the requirements shown in the following table: SECTION 51 CONCRETE STRUCTURES Quality characteristic Test method Requirement Compressive strength (psi, min): at 3 hours at 24 hours California Test 551 3,000 5,000 Flexural strength at 24 hours (psi, min) California Test 551 500 Bond strength at 24 hours (psi, min): Saturated surface dry concrete Dry concrete California Test 551 300 Water absorption (%, max) California Test 551 10 Abrasion resistance at 24 hours (g, max) California Test 550 25 Drying shrinkage at 4 days (%, max) ASTM C596 0.13 Soluble chlorides by weight (%, max) California Test 422 0.05 Water soluble sulfates by weight (%, max) California Test 417 0.25 Magnesium phosphate concrete must be formulated for a minimum initial set time of 15 minutes and minimum final set time of 25 minutes at 70 degrees F. Store the materials in a cool, dry environment before use. The mix water used with water -activated material must comply with section 90 -1.02D. The quantity of water for single -component type or liquid activator for dual -component type to be blended with the dry component, must be within the limits recommended by the manufacture r and must be the least quantity required to produce a pourable batter. If authorized, you may add retarders to magnesium phosphate concrete. The addition of retarders must comply with the manufacturer's instructions. Magnesium phosphate concrete must not be mixed in containers or worked with tools containing zinc, cadmium, aluminum, or copper metals. Modified high -alumina -based concrete must not be mixed in containers or worked with tools containing aluminum.

51-1.02D Rapid Strength Concrete

For bridge de cks or PCC deck overlays:

51-1.02E Colored Concrete

Color pigments for colored concrete must be iron oxides complying with ASTM C979/C979M. The dosage must not exceed 10 percent by weight of cementitious material in the concrete m ix design. When test panels are specified, cementitious materials and aggregates from the same sources used in the authorized test panel must be used for the colored concrete in the completed work.

51-1.02F Mortar

Mortar must be composed of cement, sand, and water. Materials for mortar must comply with section 90. The proportion of sand to cement measured by volume must be 2 to 1. Mortar must contain only enough water to allow placing and packing. Sand particles must be no larger than 1/2 th e size of the recess or space in which the mortar is to be placed.

51-1.02G Grout

Grout must consist of portland cement or portland limestone cement and water, with a water content of at most 4 gallons per 94 pounds of cement.

51-1.02H Chemical Adhesives

Chemical adhesives for bonding dowels must be on the Authori zed Material List for chemical adhesives and must be appropriate for the installation conditions of the project.

51-1.02I Miscellaneous Metal

Materials for access opening covers for new structures must comply with section 75 -3. Metal frames, covers, grate s, and other miscellaneous iron and steel used with drainage inlets must comply with section 75 -2.

51-1.02J Miscellaneous Materials

Plastic pipe for deck bleeder drains must be schedule 40 PVC complying with ASTM D1785. Galvanized wire cloth for deck blee der drains must be 1/4 -inch mesh with 0.047 -inch-diameter wire.

51-1.03 Construction

51-1.03A General

Reserved

51-1.03B Methods and Equipment

Vehicles weighing over 1,000 lb are not allowed on any bridge span until the concrete attains a compressive str ength of at least 2,400 psi. Vehicles weighing over 4,000 lb are not allowed on any span until the concrete attains a compressive strength of at least 3,250 psi or attains an age of 28 days. Vehicles exceeding the weight limitations in Veh Code Div 15 that cross bridges as allowed in section 5 - 1.37B must not make repetitive crossings of any span until the concrete attains an age of 28 days. Vehicles with a gross weight over 10,000 lb are not allowed on any span of PS concrete structures until the prestressi ng steel for that span is tensioned. If authorized, you may precast structural elements not designated as PC members. You may use the slip form method for constructing pier shafts if (1) the results are equal to those obtained by compliance with these spec ifications and (2) adequate arrangements are made and carried out for curing, finishing, and protecting the concrete. When slip forms are used for pier construction, the line and grade furnished by the Engineer is limited to establishing control points and checks of slip form position. You must provide targets, markers, or other devices for the Engineer to determine the pier shaft position. Shotcrete is not allowed as an alternative construction method for reinforced concrete members. You may construct warp ed portions of wingwalls at the ends of culverts using shotcrete complying with section 53 -1. SECTION 51 CONCRETE STRUCTURES You may use PC drainage inlets as an alternative to CIP drainage inlets.

51-1.03C Preparation

51-1.03C(1) General

Bottom of footing elevations shown are approxi mate. The Engineer may order changes in footing dimensions or elevations. Where a roughened concrete surface is described, roughen the existing concrete surface to a full amplitude of approximately 1/4 inch by abrasive blasting, water blasting, or using mechanical equipment. Pump water from the interior of foundation enclosures without removing concrete materials. Do not pump water during concrete placement or for 24 hours after placing concrete, unless the pumping is done from a sump separated from the concrete work.

51-1.03C(2) Forms

51-1.03C(2)(a) General

Forms must be:

51-1.03C(2)(b) Removing Forms

Remove all forms, except soffit forms for deck slabs of CIP box girders, forms for the interior voids of PC members, and the forms in hollow abutments or piers may remain in place for any of the following conditions:

51-1.03C(2)(c) Permanent Steel Deck Forms

51-1.03C(2)(c)(i) General

Permanent steel deck forms and supports must comply with ASTM A653/A653M, Designation SS, Grades 33 through 80, coating designation G165. Permanent steel deck forms are only allowed where shown or if specified as an option in the special provisions.

51-1.03C(2)(c)(ii) Design Requi rements

Design permanent steel deck forms based on the combined dead load of forms, reinforcement, and plastic concrete with an allowance for construction loads of at least 50 psf. The combined dead load must be assumed to be at least 160 pcf for normal co ncrete and 130 pcf for lightweight concrete. Configure forms such that the weight of deck slab and forms is at most 110 percent of the weight of the deck slab as shown. Compute the physical design properties under AISI's North American Specification for th e Design of Cold - Formed Steel Structural Members . The design span for form sheets is the clear span of the form plus 2 inches, measured parallel to the form flutes. Maximum allowable stresses and deflections are as follows:

51-1.03C(2)(c)(iii) Installation

Do not weld steel deck forms to flanges of steel girders. Permanent steel deck forms must not interfere with movement at deck expansion joints. Clearance between deck forms and bar reinforcement must be at least 1 inch. Do not use permanent steel deck forms for sections of deck slabs with longitudinal expansion joints unless additional supports are placed under the joint. Tie permanent steel deck forms together mechanically along their common edges. Do not rest form sheets directly on top of girder flanges. Fasten sheets securely to form supports. Provide at least 1 inch of bearing at each end. Place form supports in direct contact with girder flanges. Attach supports using bolts, clips, or other authorized means. Locate transverse deck construction joints at the bottom of flutes. Field drill 1/4 -inch weep holes at not less than 12 inches on cent er along the joint line. Repair galvanized form surfaces damaged before installation by wire brushing to remove loose and cracked coating and applying 2 coats of zinc -rich primer. Do not use aerosol cans. Minor heat discoloration in welded areas does not n eed to be repaired .

51-1.03D Placing Concrete

51-1.03D(1) General

Thoroughly moisten forms and subgrade with water immediately before placing concrete . Place and consolidate concrete using methods that (1) do not cause segregation of the aggregate and (2) produce dense, homogeneous concrete without voids or rock pockets. Place concrete while fresh and before initial set. Do not retemper partially hardened concrete with additional water. SECTION 51 CONCRETE STRUCTURES Place concrete continuou sly in each integral part of the structure. Do not start work unless placement can be completed uninterrupted. Place concrete for girder spans in at least 2 operations. The last operation must consist of placing the deck slab. Allow at least 5 days between operations. Place concrete as close to its final position as possible. Do not use vibrators for extensive shifting of concrete. Except for CIP piles, do not allow fresh concrete to fall more than 8 feet without using pipes, tubes, or double belting to pre vent segregation. Do not use double belting unless the member thickness is less than 16 inches. Except for concrete placed as pipe culvert headwalls and endwalls, slope paving and aprons, and concrete placed under water, consolidate concrete using high -frequency internal vibrators within 15 minutes of placing concrete in the forms. Do not attach vibrators to or hold them against forms or reinforcing steel. Do not displace reinforcement, ducts, or prestressing steel during vibrating. For structure footings o ver 2.5 feet in depth that have a top layer of reinforcement, reconsolidate the concrete to a depth of 1 foot after placing, consolidating, and initial screeding of the concrete. Reconsolidate the concrete as late as the concrete will respond again to vibr ation but not less than 15 minutes after the initial screeding. Vibrators used for concrete with epoxy -coated reinforcement or prestressing steel must have a resilient covering to prevent damage to the epoxy coating. If concrete is inaccessible for adequat e consolidation by other means, external vibrators must be used and the forms must be sufficiently rigid to resist displacement or damage. Do not place concrete for horizontal members until the concrete in supporting vertical members has been consolidated and settlement due to bleeding is complete. Where shown, apply a bond breaker to joint surfaces. Do not construct drainage structures to final grade until adjacent paving or surfacing is complete. If using a mobile volumetric mixer, before each work shift and after each time the mixer is washed out, discharge at least 2 cubic feet of RSC into a concrete waste container before placing RSC into the work.

51-1.03D(2) Concrete Bridge Decks and Diaphragms

For decks on structural steel, install cross frames the entire width of the bridge before placing the deck concrete. For concrete decks placed on bridges composed of continuous steel girders, place the portion of deck over the supports last. For bridges composed of simple span PC concrete girders made continuou s, place the deck (1) at least 5 days after placing the intermediate diaphragms or (2) after intermediate diaphragm concrete has attained a concrete compressive strength of at least 3,000 psi. Place end diaphragms with the portion of the deck over the supp orts last. For bridges composed of simple span PC concrete girders not made continuous, place the deck (1) at least 5 days after placing the intermediate and end diaphragms or (2) after diaphragm concrete has attained a concrete compressive strength of at least 3,000 psi. Deck closure pours must comply with the following:

51-1.03D(3) Concrete Placed Under Water

Only seal course concrete may be placed under water. SECTION 51 CONCRETE STRUCTURES If the Engineer determines that it is impossible or inadvisable to dewater excavations before placing concrete, place a seal course under the water using a tremie or a concrete pump. The seal cours e must be at least 2 feet thick and thick enough to seal the cofferdam. The tremie must be a watertight tube at least 10 inches in diameter with a hopper at the top. When concrete is deposited into the hopper, flow is induced by raising the discharge end. Equip discharge and tremie tubes with a device to prevent water from entering the tube when charging the tube with concrete. Support the tubes so as to allow for free movement of the discharge end over the entire work surface and rapid lowering of the tube . Fill the tubes using a method that prevents washing of the concrete. Keep the discharge end submerged in the concrete at all times. The tube must contain enough concrete to prevent water entry. Place the concrete carefully in a compact mass. Concrete flow must be continuous until completion of the seal course. The seal course must be monolithic and homogeneous. Do not disturb concrete after placement. Maintain still water at the point of placement. Cure the seal course concrete for at least 5 days before dewatering the cofferdam. Increase the curing time for seal course concrete placed in water that is below 45 degrees F. Periods of time when the water temperature is continuously below 38 degrees F is not considered as curing time. Dewater the cofferdam after the seal course has adequate strength to resist the hydrostatic load. After dewatering, clean the top of the concrete of all scum, laitance, and sediment. Remove local high spots to provide the specified clearance for reinforcing steel befo re placing fresh concrete.

51-1.03D(4) Construction Joints

Place construction joints only where described unless authorized. At horizontal construction joints:

51-1.03D(5) Colored Concrete

When placing colored concrete :

51-1.03D(6) Bearing Surfaces

For elastomeric bearing pads, wood float finish the concrete bearing surface to a level plane that varies at most 1/16 inch from a straightedge placed in a ny direction and is within 1/8 inch of the specified elevation. The bearing area must extend at least 1 inch beyond the limits of the bearing pads. For bearing assemblies or masonry plates not embedded in concrete, construct the concrete bearing area above grade and grind to a true level plane that (1) does not vary perceptibly from a straightedge placed in any direction and (2) is within 1/8 inch of the elevation shown.

51-1.03D(7) Pier Columns

Place concrete for pier columns against firm, undisturbed foundation material on the bottom and sides of the pier column excavations except place concrete against forms where shown. Immediately before placing concrete, all excavated surfaces against which the concrete is to be placed must be free from standing water, ice, mud, debris, and loose material.

51-1.03E Miscellaneous Construction

51-1.03E(1) General

Where shown, paint the structure name, bridge number, year constructed, and other bridge identification information. Painting concrete must comply with section 78 -4.03C(3). Bridge identification on the bridge barrier must comply with section 83 -1.03D. Bridge identification on the bridge substructure must be (1) painted at each structure approa ch facing and

51-1 02c.

51-1.03E(2) Placing Mortar

Place mortar in recesses and holes, on surfaces, under structural members, and at other locations wh ere described. Clean concrete areas to be in contact with mortar of loose or foreign material that would prevent bonding between the mortar and the concrete surfaces. Flush the concrete areas with water and allow them to dry to a surface -dry condition imme diately before placing the mortar. Tightly pack mortar to completely fill spaces. Locations where mortar can escape must be mortar -tight before placing mortar. Cure mortar for 3 days using the water method under section 90 -1.03B. Do not load mortar until 7 2 hours after placement unless authorized.

51-1.03E(3) Drill and Bond Dowels

For drill and bond dowels, drill the holes without damaging the adjacent concrete. Holes for bonded dowels must be 1/2 inch larger than the nominal dowel diameter. If reinforcement is encountered during drilling before the specified depth is attained, notify the Engineer. Unless coring through the reinforcement is authorized. Drill a new hole adjacent to the rejected hole to the depth shown. SECTION 51 CONCRETE STRUCTURES Coat the surface of any dowel coated with zinc or cadmium with a colored lacquer. Allow the lacquer to dry thoroughly before installing the dowel. Each drilled hole must be clean and dry when placing the bonding material and dowel. The bonding material and dowel mu st completely fill the drilled hole. The surface temperature must be at least 40 degrees F when magnesium phosphate concrete is placed. Thoroughly dry finishing tools cleaned with water before working magnesium phosphate concrete. Leave dowels undisturbed for 3 hours or until the dowels can be supported by the concrete. Cure modified high -alumina -based concrete and portland -cement -based concrete using the curing compound method. Do not cure magnesium phosphate concrete. Replace dowels that fail to bond or a re damaged.

51-1.03E(4) Drill and Grout Dowels

Drill the holes under section 51 -1.03E(3). For drill and grout dowels, drill the holes 1/4 inch larger than the nominal dowel diameter. Immediately before placing dowels, holes must be cleaned, be thoroughly saturated with water, have all free water removed, and be dried to a saturated surface dry condition. Place grout into the holes and insert the dowels. Retempering of grout is not allowed. Cure grout at least 3 days or until the dowels are encased in concr ete. Immobilize the dowels during the curing period. Cure using curing compound method or by keeping the surface continuously damp. Replace dowels that fail to bond or are damaged.

51-1.03E(5) Drill and Bond Dowel —Chemical Adhesive

Install dowels for the drill and bond dowel chemical adhesive system under the manufacturer's instructions. When installing dowels in new concrete, install after the concrete has cured for at least 28 days. Drill the holes without damaging the adjacent concrete. Remove all l oose dust and concrete particles from the hole and protect the hole from deleterious materials until the anchor is installed. If reinforcement is encountered during drilling before the specified depth is attained, notify the Engineer. Unless coring through the reinforcement is authorized. Drill a new hole adjacent to the rejected hole to the depth shown. Immediately after inserting the dowel into the chemical adhesive, support the dowel as necessary to prevent movement until the chemical adhesive has cured the minimum time specified in the manufacturer's instructions. Dowels must not be adjusted by bending. The adhesive must be fully cured before the dowel is put into service. Replace dowels that fail to bond or are damaged.

51-1.03E(6) Nonskid Abrasive Fin ish

Where shown, place a nonskid abrasive finish on pedestrian walkways, stair treads, and landings. The nonskid finish must consist of commercial -quality aluminum oxide, silicon carbide, or almandite garnet grit particles, sieve size no. 12 to 30 or no. 14 to 35. Uniformly apply grit particles at a rate of at least 0.3 lb/sq ft onto the floated concrete surface while the concrete is plastic. Bury the particles into the concrete to a depth of approximately 0.7 times the diame ter of each particle.

51-1.03E(7) Drains in Walls

Where shown, construct drain holes and weep holes in abutment walls, wingwalls, and retaining walls. Cover retaining wall and abutment wall drains at the back face of the wall with 1/4 -inch mesh, 0.025 -inch- diameter aluminum or galvanized steel wire hardware cloth. Mount hardware cloth in forms before pouring concrete or fasten the cloth to the exterior concrete surface with masonry nails. In addition to wall drains, i nstall hydrostatic pressure relief holes 3 inches in diameter at the bottom of walls immediately above footings at approximately 15 -foot centers. SECTION 51 CONCRETE STRUCTURES

51-1.03E(8) Deck Bleeder Drains

The Engineer provides the exact location for each deck bleeder drain . Drill the holes for drains in existing bridges using a diamond core drill bit. Do not spall hole edges. Holes must be 2 inches in diameter. Install drains such that the top of the pipe is approximate ly 1/4 inch below the concrete deck surface. Replace drains out of position as determined by the Engineer. Secure plastic pipe installed in existing bridges with an epoxy adhesive. Score the outside surfaces of the pipe before installing the pipe. Spread e poxy on both the pipe and hole surfaces. Epoxy must completely fill the space between the pipe and the hole. Install drains before placing the deck seal. Center the wire cloth above the drains. Place the cloth after placing the deck seal and before placing the HMA. Secure the cloth using an authorized method to prevent movement during HMA placement. Do not damage the deck seal.

51-1.03E(9) Utility Facilities

Where shown, utility facilities will be carried in or on structures. Install hangers, anchor bolt inserts, manhole frames and covers, sleeves, and other accessories required for the utility facility that must be cast in the concrete. The utility owner will furnish these items. The utility owner will furnish and install conduct ors and casings when the structure is ready for the installation and before any work that interferes with installation is started. Notify the Engineer at least 30 days before the date structures are ready for utility installation. The Engineer will notify the utility owner.

51-1.03E(10) Concrete Headers and Steel Plates

Concrete for concrete headers must comply with the specifications for minor concrete. Steel plates and attachment hardware must comply with section 75 -1 except that galvanizing is not requi red.

51-1.03E(11) Diaphragm Bolsters

Reserved

51-1.03E(12) Hinge Tiedowns

Reserved

51-1.03F Finishing Concrete

51-1.03F(1) General

Strike off exposed surfaces of consolidated concrete to the lines and grades shown. Provide a uniform surface texture having the specified finish without undulations or irregularities. The Engineer determines the acceptability of the surface finishes. Finish sidewalks, curbs, and st airways on structures under section 73 -3 except surfaces are not marked.

51-1.03F(2) Ordinary Surface Finish

Apply ordinary surface finish to all concrete surfaces as a final finish or before applying a higher class finish. Ordinary surface finish must be the final finish for the following surfaces:

51-1.03F(3) Class 1 Surface Finish

Class 1 surface f inish includes finishing concrete surfaces to produce smooth, even surfaces of uniform texture and appearance without bulges, depressions, or other imperfections. Class 1 surface finish must be the final surface finish for th e following surfaces:

51-1.03F(4) Class 2 Surface Finish

Where a Class 2 surface finish is described:

51-1.03F(5) Finishing Roadway Surfaces

51-1.03F(5)(a) General

Construct concrete roadway surfaces of structures, approach slabs, sleeper slabs, and adjoining approach pavement, and concrete d ecks to be covered with another material, to the grade and cross section shown. Surfaces must comply with the specified smoothness, surface texture, and surface crack requirements. The Engineer sets deck elevation control points for your use in establishin g the grade and cross section of the deck surface. The grade established by the deck elevation control points includes all camber allowances. Elevation control points will not be closer together than approximately 8 feet longitudinally and 24 feet transver sely to the bridge centerline. Before starting concrete placement for any deck section:

51-1.03F(5)(b) Bridge Deck Surface Texture

51-1.03F(5)(b)(i) General

Except for bridge widenings and bridge decks to be covered with an overlay, texture roadway surfaces of bridge decks, approach slabs, and sleeper slabs, and other roadway surfaces of concrete str uctures longitudinally by grinding and grooving or by longitudinal tining. For bridge widenings, texture the roadway surfaces longitudinally by longitudinal tining. For bridge decks that are to be covered with an overlay, texture the deck using a burlap dr ag or broom device that produces striations either parallel or transverse to the centerline. If these structures are opened to traffic before the overlay is placed, the deck surface must meet the coefficient of friction requirement in section 51 -1.01D(3)(b )(iii). SECTION 51 CONCRETE STRUCTURES

51-1.03F(5)(b)(ii) Grinding and Grooving

When texturing the deck surface by grinding and grooving, place a 1/4 inch of sacrificial concrete cover on the bridge deck above the finished grade shown. Place items to be embedded in the concrete based on the final profile grade elevations shown. Construct joint seals after completing the grinding and grooving. Before grinding and grooving, deck surfaces must comply with the smoothness and deck crack treatment requirements. Grind and groove the deck surfa ce to within 18 inches of the toe of the barrier as follows:

51-1.03F(5)(b)(iii) Longitudinal Tining

When texturing the deck surface by longitudinal tining, perform initial texturing with a burlap drag or broom device that produces striations parallel to the centerline. Perform final texturing with spring steel tines that produce grooves parallel with the centerline. The tines must:

51-1.03F(6) Finishing Pedestrian Overcrossing Surfaces

Construct deck surfaces, including ramps and landings of POCs to the grade and cross section shown. Surfaces must comply with the specified smoothness, surface texture, and surface crack requirements. The Engineer sets deck elevation control points for your use in establishing the grade and cross section of the deck surface. The grade established by the deck elevation control points includes all camber allowances. Except for landings, elevation control points include the beginning and end of the ramp and will not be closer together than approximat ely 8 feet longitudinally and 4 feet transversely to the POC centerline. Landing elevation control points are at the beginning and the end of the landing. Broom finish the deck surfaces of POCs. Apply the broom finish perpendicular to the path of travel. Y ou may apply water mist to the surface immediately before brooming. Clean any discolored concrete by abrasive blast cleaning or other authorized methods. POC deck surfaces must comply with the following smoothness requirements:

51-1.03G Concrete Surface Textures

51-1.03G(1) General

Provide the concrete surface textures shown. The Engineer determines the acceptability of the surface textures. SECTION 51 CONCRETE STRUCTURES Construct a test panel for each type of concrete surface text ure shown. Fractured rib texture must consist of straight ribs of concrete with a fractured texture on the raised surface between ribs. Grooves between ribs must be (1) continuous with no apparent curves or discontinuities and (2) straight to within 1/4 inch in 10 feet. The texture must have random shadow patterns. Broken concrete at adjoining ribs and groups of ribs must have a random pattern. The texture must not have repetitive fractured surfaces or secondary shadow patterns . Heavy blast texture must consist of an abrasive -blasted concrete surface of uniform color and sandy texture with air and water bubbles in the concrete partially exposed. Formed relief texture must consist of a formed relief constructed to the dimensions and shapes shown with a Class 1 surface finish. Intersecting corners of plane surfaces must be sharp and crisp without easing or rounding. Cure concrete surface textures by the forms -in-place or water methods.

51-1.03G(2) Form Liners

Use form liners for concrete surface textures except for heavy blast and formed relief textures. Other forming methods must be authorized. Form liners must (1) be manufactured from an elastomeric material by a manufacturer of commercially available concrete form liners and (2) leave a crisp, sharp definition of the concrete surface texture. Form liners must comply with the requirements shown in the foll owing table: Quality characteristic Test method Requirement Shore A hardness ASTM D2240 50–90 Tensile strength (psi, min) ASTM D412 1,000 Comply with the form liner manufacturer's instructions for use. Seal and repair cuts and tears in form liners under the form liner manufacturer's instructions. Do not use form liners that are delaminated or deformed. Extend form liners the full length of texturing, with transverse joints at 8 -foot minimum spacing. Do not use small pieces of form liners. Ali gn grooves straight and true. Grooves must match at joints between form liners. For grooved patterns, joints in the direction of grooves must be located in depressions. Butt adjoining liners together without distortion, open cracks, or offsets. Clean joint s between liners and remove mortar before use. Adhesives must be compatible with the form liner material and the concrete. Adhesives must be recommended by the liner manufacturer and not cause swelling of the liner material. Cast form liner patterns to pre vent recurring textural configurations exhibited by repeating, recognizable shadow patterns. Remove surfaces with recurring textural configurations by reworking using authorized methods or by replacement. Use a form release agent recommended by the form li ner manufacturer. The release agent must not:

51-1.03H Curing Concrete Structures

Except for bridge decks, cure newly placed concrete for CIP structures using the water method or the forms -in-place method under section 90 -1.03B. Cure the top surface of bridge decks by (1) misting and (2) the water method using a curing medium under section 90 -1.03B(2). After strike -off, immediately and continuously mist t he deck with an atomizing nozzle that forms a mist and not a spray. Continue misting until the curing medium has been placed and the application of water for the water method has started. At the end of the curing period, remove the curing medium and apply curing compound on the top surface of the bridge deck during the same work shift under section 90 -1.03B(3). The curing compound must be curing compound no. 1. Cure the top surface of bridge decks to be sealed with butyl rubber membrane using only the water method. You may use a pigmented curing compound complying with section 90 -1.03B(3) for:

51-1.03I Protecting Concrete Structures

Maintain concrete at a temperature of not less than 45 degrees F for 72 hours after placing and at not less than 40 degrees F for an additional 4 days.

51-1.03J Temporary Decking

If you are unable to complete bridge reconstruction activities before the bridge is to be opened to traffic, furnish and maintain temporary decking under section 48 -4 until that portion of the work is complete.

51-1.04 Payment

The payment quantity for seal course concrete is the actual volume of seal course concrete placed except the maximum payment quantity is the volume of concrete contained between vertical planes 1 foot outside the neat lines of the seal course show n. The Department does not adjust the unit price for an increase or decrease in the seal course concrete quantity. The payment quantity for structural concrete, drainage inlet is the volume determined from the dimensions shown for CIP drainage inlets. SECTION 51 CONCRETE STRUCTURES

51-2 Joints

51-2.01 General

51-2.01A General

51-2.01A(1) Summary

Section 51 -2.01 includes general specifications for constructing, sealing, and protecting joints in concrete structures. The specifications for (1) shrinkage in section 90 -1.02A, (2) shrinkage reducing chemical admixture in section 51 -1.02B, and (3) polymer fibers in section 51 -1.02B do not apply to concrete used to fill blocked - out recesses for joint seal assemblies.

51-2.01A(2) Definitions

Reserved

51-2.01A(3) Submittals

Submit a c ertificate of compliance for glass fiber reinforced acetal copolymer material for snowplow deflectors.

51-2.01A(4) Quality Assurance

Reserved

51-2.01B Materials

51-2.01B(1) General

Premolded expansion joint filler must comply with ASTM D1751. Expanded polystyrene must be commercially available polystyrene board with (1) a flexural strength of at least 35 psi when tested under ASTM C203 and (2) a compressive yield strength from 16 to 40 psi at 5 percent compression. Face the surfaces of expanded polystyrene that concrete is placed against with 1/8-inch-thick hardboard complying with ANSI A135.4. You may use other facing materials that provide equivalent protection. Secure the hardboard u sing nails, waterproof adhesive, or other authorized means.

51-2.01B(2) Snowplow Deflectors

Snowplow deflectors must consist of glass fiber reinforced acetal copolymer plates with anchorage devices, silicone sealant, bonding materials, and threaded inserts. Anchorage devices must comply with ASTM A276, UNS designation S32205 or S31803. Glass fiber reinforced acetal copolymer plates must comply with ASTM D6778 and the requirements shown in the following table: Quality characteristic Test method Requirement Glass fiber (%, min) -- 25 Density (pcf, min) ASTM D792 94 Tensile strength, ultimate (psi, min) ASTM D638 15,000 Elongation at break (%, max) ASTM D638 3 Tensile modulus (psi, min) ASTM D638 1.00 x 106 Flexural strength (psi, min) ASTM D790 20,000 Flexural modulus (psi, min) ASTM D790 0.90 x 106

51-2.01C Construction

51-2.01C(1) General

Construct open joints using a suitable material that you subsequently remove. Do not chip or break concrete corners when removing the material. Reinforcement must not extend across an open joint. For filled joints, place premolded or expanded polystyrene j oint filler in position before placing concrete. Fill holes and joints with mastic to prevent the passage of mortar or concrete. Finish concrete edges at joints using an edger. SECTION 51 CONCRETE STRUCTURES

51-2.01C(2) Snowplow Deflectors

Drilling and bonding anchorage devices must comply with the specifications for drilling and bonding dowels in section 51 -1.03E(3). Apply a thread -locking system to the anchorage devices under section 75 -3.02B.

51-2.01D Payment

Not Used

51-2.02 Sealed Joints

51-2.02A General

51-2.02A(1) Gene ral

51-2.02A(1)(a) Summary

Section 51 -2.02 includes general specifications for fabricating and installing sealed joints . Sealed joints must:

51-2.02A(1)(b) Definitions

Lot: Elastomer from the same batch.

51-2.02A(1)(c) Submittals

Submit a work plan for cleaning expansion joints. Include details for preventing material, equ ipment, or debris from falling onto traffic or railroad property.

51-2.02A(1)(d) Quality Assurance

Reserved

51-2.02A(2) Materials

For metal surfaces in joint seal assemblies, except for stainless steel, you must either:

51-2.02A(3) Construction

The Engineer may order you to install a joint seal larger than required by the MR. This work is change order work. The joint opening at the time of placement must be that shown adjusted for temperature. Do not impair the joint clearance. Cover or otherwise protect joints at all times before joint seals are installed. Do not allow debris or foreign material to enter joints. Clean expansion joints at existing bridges before installing joint seals. Remove all existing seal material, dirt, debris, damaged waterstops, and joint filler. Use methods that do not damage existing sound concrete. Verify the join t size after cleaning. Clean existing joints with undamaged waterstops to the top of the waterstop unless the waterstop is to be removed. SECTION 51 CONCRETE STRUCTURES Clean existing joints without waterstops and joints with damaged waterstops down to the hinge or bearing seat. Repair joint damage as ordered. Cleaning joints below existing waterstops that are damaged and repairing existing joint damage is change order work. After concrete reaches initial set, the Engineer determines when to release the temporary joint supports.

51-2.02A(4) Payment

Joint seals and joint seal assemblies are measured from end to end along the centerline of the completed seal, including return sections and curb faces.

51-2.02B Type A and AL Joint Seals

51-2.02B(1) General

51-2.02B(1)(a) Summary

Section 5 1-2.02B includes specifications for installing Type A and AL joint seals . Type A and AL joint seals consist of field -mixed silicone sealant placed in grooves in the concrete .

51-2.02B(1)(b) Definitions

Reserved

51-2.02B(1)(c) Submittals

At least 15 days before delivery to the job site, submit a certificate of compliance, SDS, and manufacturer's instructions for:

51-2.02B(1)(d) Quality Assurance

Reserved

51-2.02B(2) Materials

51-2.02B(2)(a) General

Reserved

51-2.02B(2)(b) Type A and AL Joint Seal

Type A and AL joint seals must be on the Authorized Materials List for type A and AL joint seals. Label sealant containers or provide identification tickets for tanks of 2 -component material. Include the following:

51-2.02B(2)(c) Backer Rods

Polyethylene foam or rod stock for retaining sealant must be commercial quality with a continuous, impervious glazed surface.

51-2.02B(3) Construction

51-2.02B(3)(a) General

Do not use sealant or adhesive that has skinned over. Do not use liquid components that have been exposed to air. SECTION 51 CONCRETE STRUCTURES Apply sealant or adhesive when concrete surface temperature is at least 40 degrees F. Abrasive blas t clean joints and remove foreign material with high -pressure air immediately before installing seals. Protect waterstops during cleaning. Joint surfaces must be surface dry when seals are installed . Place the sealant using equipment that mixes and extrudes the sealant into the joint. The equipment and the sealant placement must be as recommended by the sealant manufacturer. Do not hand mix sealant . Do not expose sealant to air prior to mixing .

51-2.02B(3)(b) Type A Seal Preparation

Do not start cut ting grooves until joint material is delivered to the job site. Concrete saws for cutting grooves in the concrete must have diamond blades with a minimum thickness of 3/16 inch. Cut both sides of the groove simultaneously for a minimum 1st pass depth of 2 inches. The completed groove must have:

51-2.02B(3)(c) Type AL Seal Preparation

For Type AL joint seals, remove expanded polystyrene and foreign material to the depth of the joint seal. Grind or edge the lip of the joint.

51-2.02B(4) Payment

Not Used

51-2.02C Type B Joint Seals

51-2.02C(1) General

51-2.02C(1)(a) Summary

Section 51 -2.02C includes specifications for instal ling Type B joint seals . SECTION 51 CONCRETE STRUCTURES Type B joint seals consist of preformed elastomeric joint seals placed in grooves in the concrete.

51-2.02C(1)(b) Definitions

Reserved

51-2.02C(1)(c) Submittals

Submit a certificate of compliance with certified test report for each lot of elastomeric joint seal and lubricant -adhesive. Test reports must include the seal MR, the manufacturer's minimum uncompressed width, and test results. Submit each joint seal test sample selected by the Engineer for testing with its certificate of compliance at least 30 days before use.

51-2.02C(1)(d) Quality Assurance

51-2.02C(1)(d)(i) General

Reserved

51-2.02C(1)(d)(ii) Quality Control

The Engineer selects test samples of join t seal material and lubricant -adhesive at random from each lot of material. Test samples are selected from stock at the job site or at a location acceptable to the Engineer and the manufacturer. Joint seal test samples must be at least 3 feet long. If samples are selected at the job site, submit test samples to METS and notify the Engineer. Demonstrate the adequacy of installation procedures for Type B seals before starting installation activities.

51-2.02C(1)(d)(iii) Department Acceptance

Reserved

51-2.02C(2) Materials

Preformed elastomeric joint seals must:

51-2.02C(3) Construction

Prepare joints under section 51 -2.02B(3)(b) except remove all material from the deck joint to the top of the waterstop or to the depth of the seal to be installed plus 3 inches. Thoroughly clean contact surfaces and the top surface of the seal to within 1/2 inch from either edge immediately before applying the lubricant -adhesive. Liberally apply the lubricant -adhesive to vertical groove surfaces and the sides of the joint seal under the manufacturer's instructions. Install joint seals full length for each joint using equipment that does not distort or damage the seal or the concrete. The top edges of the installed seal must be in a plane normal to the sides of the groove. If authorized, you may make 1 field splice per joint using an authorized splicing method. Joint seals must be manufactured full le ngth and cut for the splice. The cut must be re -matched in the field before splicing. SECTION 51 CONCRETE STRUCTURES All splices must have no visible offset of exterior surfaces and no evidence of bond failure.

51-2.02C(4) Payment

Not Used

51-2.02D Strip Joint Seal Assemblies with a M ovement Ra nge of 4 inches or Less

51-2.02D(1) General

51-2.02D(1)(a) Summary

Section 51 -2.02D includes specifications for fabricating and installing strip joint seal assemblies with an MR of 4 inches or less. Strip joint seal assemblies with an MR of 4 inches or less consist of metal or metal and elastomeric assemblies placed in recesses over joints. Strip joint seal assemblies consist of a 1 joint cell. You may use an alternative joint seal assembly if:

51-2.02D(1)(b) Definitions

Reserved

51-2.02D(1)(c) Submittals

51-2.02D(1)(c)(i) General

For alternative joint seal assemblies, submit a certificate of compliance for each shipment of joint seal materials. The certificate must state that the materials and fabrication involved comply with the specifications and the data submitted in obtaining the authorization for the alternative joint seal assembly.

51-2.02D(1)(c)(ii) Shop Drawings

Submit shop drawings for each alternative joint seal assembly electronically to sc.office.associates@dot.ca.gov . Include details of the joint seal assembly and anchorage components, method of installation, blockout details, and additions or rearrangements of reinforcing steel. If requested, submit supplemental calculations for each proposed alternative joint seal assembly electronically to sc.office.associates@dot.ca.gov . Shop drawings must include the thermal equation used for setting the minimum joint openin g at installation. The thermal equation must be based on the structur e temperature. Shop drawings and calculations must be sealed and signed by an engineer who is registered as a civil engineer in the State . Allow 25 days for the Department's review.

51-2.02D(1)(d) Quality Assurance

Reserved

51-2.02D(2) Materials

51-2.02D(2)(a) General

Metal parts must comply with section 55 -1.02D(3) or with ASTM A 36/A36M, except b olts, nuts, and washers must comply with the specifications for components of HS steel fast ener assemblies for use in HS joints in section 75 -1. Stud connectors must comply with AWS D1.5, Type B. SECTION 51 CONCRETE STRUCTURES Sheet neoprene must comply with the specifications for neoprene in section 51 -2.02E(2)(a). Fabricate sheet neoprene to fit the joint seal assembly accu rately. Neoprene gland must be continuous without field splices.

51-2.02D(2)(b) Alternative Strip Joint Seal Assemblies, Movement Range of 4 inches or Less

Alternative strip joint seal assemblies must have CIP anchorage components for casting into the dec k. The anchorage components must include anchor studs spaced at a maximum of 4 -1/2 inches. The studs must be at least 5/8 inch in diameter and 8 inches long, except the studs may be 6 inches long in the overhang. Elastomer must be neoprene complying with t he specifications for neoprene in section 51 -2.02E(2)(a). The design loading must be the AASHTO LRFD Bridge Design Specifications Design Truck with 75 percent dynamic load allowance. The tire contact area must be 10 inches measured normal to the longitudin al assembly axis by 20 inches wide. The assembly must provide a smooth -riding joint without slapping of components or tire rumble. During installation, measure dimensions for positioning the assembly normal to the longitudinal axis of the assembly. The max imum depth and width of the recess must be such that the primary reinforcement providing the necessary strength of the structural members is outside the recess. The maximum depth at abutments and hinges is 10 inches. The maximum width on each side of the e xpansion joint is 12 inches. Horizontal angle points and vertical corners at curbs must be premolded sections or standard sections of the assembly that have been miter cut or bent to fit.

51-2.02D(3) Construction

Deck surfaces must comply with section 51 -1.03F(5) before placing and anchoring joint seal assemblies. POC deck surfaces must comply with section 51 -1.03F(6) before placing and anchoring joint seal assemblies. Preassemble metal parts of assemblies before installation to verify geometry. Except for primary reinforcement, continue reinforcement through the recess construction joint into the recess and engage anchorage components of the assembly. Thoroughly clean joints immediately before installing sheet neoprene. Install sheet neoprene at such time that it will not be damaged by construction activities. Place the assembly in the blocked -out recess in the concrete deck surface. The depth and width of the recess must allow the installation of the assembly anchorage components or anchorage be aring surface to the lines and grades shown. For alternative joint seal assemblies, install elastomer under the manufacturer's instructions. Thoroughly clean the joint and blockout immediately before elastomer installation.

51-2.02D(4) Payment

Not Used

51-2.02E Modular Joint Seal Assemblies with a Movement Ra nge Over 4 inches

51-2.02E(1) General

51-2.02E(1)(a) Summary

Section 51 -2.02E includes specifications for fabricating and installing joint seal assemblies with an MR over 4 inches. Joint seal assemblies consist of metal or metal and elastomeric assemblies anchored or cast into a recess in the concrete over the joint.

51-2.02E(1)(b) Definitions

Reserved SECTION 51 CONCRETE STRUCTURES

51-2.02E(1)(c) Submittals

51-2.02E(1)(c)(i) General

Reserved

51-2.02E(1)(c)(ii) Shop Drawings

Submit shop drawings for each joint seal assembly electronically to sc.office.associates@dot.ca.gov . If request ed, submit supplemental calculations for each proposed modular joint seal assembly electronically to sc.office.associates@dot.ca.gov . Shop drawings and calculations must be sealed and signed by an engineer who is registered as a civil engineer in the State . Shop drawings must include the thermal equation used for setting the minimum joint opening at installation. The thermal equation must be based on the structure temperature . Allow 30 days for the Department's review. Include details of the joint seal asse mbly and anchorage components, method of installation, blockout details, and additions or rearrangements of reinforcing steel.

51-2.02E(1)(c)(iii) Certificate of Compliance

Submit a certificate of compliance for each shipment of joint seal assembly materials.

51-2.02E(1)(d) Quality Assurance

51-2.02E(1)(d)(i) General

Vertical expansion joints in barriers must be accessible for inspection after recess concrete is placed. Modular joint seal assemblies will not be authorized without evidence of 3 years of satisfactory service in the United States.

51-2.02E(1)(d)(ii) Quality Control

A qualified representative of the assembly manufacturer must be present during the installation of the 1st assembly and available during remaining installations.

51-2.02E(1)(d)(iii) Department Acceptance

Reserved

51-2.02E(2) Materials

51-2.02E(2)(a) General

Metal parts must comply with section 55 -1.02D(3) or with ASTM A 36/A36M, except b olts, nuts, and washers must comply with the specifications for components of HS steel fastener assemblies for use in HS joints in section 75 -1. Stud connectors must comply with AWS D1.5, Type B. Joint seal assemblies must consist of a metal frame system, supporting rails, and support bars with intervening neoprene glands. Neoprene glands must comply with specifications for neoprene in section 51 -2.02E(2)(a). Anchorage components must include anchor studs spaced at a maximum of 4 -1/2 inches. Studs must be at least 5/8 inch in diameter and 8 inches long, except the studs may be 6 inch es long in the overhang. Anchorage components must be galvanized. Assemblies must be assembled completely at the fabrication site.

51-2.02E(2)(b) Design Requirements

If the assembly consists of more than 1 component, design the assembly such that the exte rnal components can be removed and reinstalled at any position within the larger half of the MR to allow for inspection of the internal components. Center beams, support bars, and other structural elements must be fatigue tested and designed under Chapter 14 of the AASHTO LRFD Bridge Design Specifications with California Amendments . SECTION 51 CONCRETE STRUCTURES The maximum width of unsupported or yielding components or grooves in the roadway surface of the assembly must be 3 inches measured in the direction of travel. Assemblies must b e capable of adjustment to the "a" dimension shown. The assembly must have CIP anchorage components that form a mechanical connection between the joint components and the concrete deck. Welds in center beams, yokes, stirrups, and other structural elements must be:

51-2.02E(3) Construction

Measure dimensions for positioning the assembly during installation normal to the longitudinal axis of the assembly, disregarding the skew of the deck expansion joint. Deck surface s must comply with section 51 -1.03F(5) before placing joint seal assemblies and anchorages. Place each assembly into a blocked -out recess in the concrete deck surface. The depth and width of the recess must allow the installation of the assembly anchorage components or anchorage bearing surface to the lines and grades shown. Except for primary reinforcement, continue reinforcement through the recess construction joint into the recess and engage anchorage components of the assembly. The Engineer may order yo u to install additional drill and bond dowel bar reinforcement. This work is change order work. If authorized, you may make a maximum of 1 field splice per joint. The field splice must:

51-2.02E(4) Payment

Not Used

51-2.02F Asphaltic Plug Joint Seals

51-2.02F(1) General

51-2.02F(1)(a) Summary

Section 51 -2.02F includes specifications for constructing asphaltic plug joint seals . Asphaltic plug joint seals consist of an asphaltic binder and aggregate joint seal system.

51-2.02F(1)(b) Definitions

Reserved

51-2.02F(1)(c) Submittals

51-2.02F(1)(c)(i) General

Reserved

51-2.02F(1)(c)(ii) Shop Drawings

Submit shop drawings for the asphaltic plug joint seal system electronically to sc.office.associates@dot.ca. gov. Allow 30 days for the Department's review.

51-2.02F(1)(c)(iii) Product Data

Submit evidence from the manufacturer that 5,000 linear feet of the joint seal has had at least 2 years of satisfactory service under similar conditions.

51-2.02F(1)(c)(iv) Certificate of Compliance

Submit certificates of compliance for materials used in the joint seals. Submit a copy of the certified test report for binder material.

51-2.02F(1)(c)(v) Samples

Submit a 10 -pound test sample of binder materi al to METS. The test sample must be removed from the same material to be shipped to the job site. Submit the test sample at least 15 days before shipment to the job site.

51-2.02F(1)(d) Quality Assurance

51-2.02F(1)(d)(i) General

Reserved

51-2.02F(1)(d)(ii) Quality Control

Binder material must be tested and certified by an authorized laboratory. A technical representative of the joint seal manufacturer must be present during installation.

51-2.02F(2) Materials

All joint components must be from a single manufacturer. The binder must be a thermoplastic, polymeric -modified asphalt; thermoplastic, polymer -modified bitumen; polymer -modified asphalt sealant; or modified elastomeric binder complying with the requirements shown in the following ta ble: SECTION 51 CONCRETE STRUCTURES Quality characteristic Test method Requirement Asphalt compatibility ASTM D5329 Pass Bond, nonimmersed at -20 °F, 50% at 0 °F, 100% ASTM D5329 Pass 3 cycles Pass 3 cycles Cone penetration, nonimmersed (mm) 200 g total weight, 60 seconds at 0 ± 2 °F 150 g total weight, 5 seconds at 77 ± 2 °F ASTM D5329 (modified) 1, min 9, max Ductility (cm, min, at 77 ± 2 °F) ASTM D113 40 Flexibility (at 10 ± 2 °F) ASTM D5329a Pass Flow (mm, max, 5 hours at 140 ± 2 °F) ASTM D5329 3 Resilience (%, min, at 77 ± 2 °F) ASTM D5329 40 Softening point (°F, min) ASTM D36 180 Tensile adhesion (%, min) ASTM D5329 550 Safe heating temperature (°F) -- 390–410 Recommended pouring temperature (°F) -- 360–390 aDo not oven age specimens. After 24 hours at standard conditions, allow specimens to condition at -10 ± 2 °F for 2 hours before testing. Binder material delivered to the job site must be labeled with:

51-2.02F(3) Construction

Uniformly double wash and dry natural aggregates before use. Remove existin g expansion dams and asphaltic concrete to the limits shown. Do not damage the deck or remaining asphaltic concrete. Steel dowels exposed when removing concrete must be cut off flush with the existing concrete or at the bottom of concrete removal, whicheve r is lower. Patching around or over dowels in sound concrete is not required. Chip voids back to sound concrete and fill voids with magnesium phosphate concrete. Clean expansion joints under section 51 -2.02C(3). Repair spalls if ordered. Repairing spalls i s change order work. Abrasive blast blockout surfaces to receive the asphaltic plug joint seal. SECTION 51 CONCRETE STRUCTURES Clean and dry blockout surfaces and the adjacent 6 inches of roadway immediately before placing the joint seal. Use a hot air lance producing a minimum temperat ure of 2,500 degrees F and a directional velocity of at least 2,500 ft/sec. There must be no moisture present during installation. Place the top of the backer rod to a depth of at least 1 inch and at most equal to the width of the existing gap below the bo ttom of the blockout. Center bridging plate sections over the existing gap. Place the sections flat on the bottom of the blockout. The sections must be butt jointed. Do not overlap the sections or allow gaps between the plate and blockout. Install the join t seal under the manufacturer's instructions.

51-2.02F(4) Payment

Not Used

51-2.02G Bonded Joint Seals

Reserved

51-2.02H Neoprene Strip Seal Glands

Reserved

51-2.03 Sliding Joints

51-2.03A General

Section 51 -2.03 includes specifications for constructing sliding joints. Sliding joints consist of neoprene strips lubricated with silicone grease and covered with sheet metal.

51-2.03B Materials

Neoprene strips must comply with the specifications for neoprene in section 51 -2.04B. Silicone grease must comply with Society of Automotive Engineers AS 8660. Sheet metal must be commercial -quality galvanized sheet steel, smooth and free of kinks, bends, or burrs. Joints must be butt joints sealed with plastic, duct -sealing tape.

51-2.03C Construction

Apply a uniform film of silicone grease to the upper surface of the neoprene strip before placing the sheet metal. Float the concrete surfaces where neoprene strips are placed to a level plane and finish with a steel trowel. Do not allow grout or concrete seepage into the sliding joint during concrete placement.

51-2.03D Payment

Not Used

51-2.04 Waterstops

51-2.04A General

51-2.04A(1) Summary

51-2.04A(2) Definitions

Reserved

51-2.04A(3) Submittals

Submit a certificate of compliance for waterstop material. The certificate of compliance for PVC waterstop must include a statement that the material complies with item 6 of Army C orps of Engineers CRD -C 572. SECTION 51 CONCRETE STRUCTURES

51-2.04A(4) Quality Assurance

Reserved

51-2.04B Materials

Waterstops must be manufactured from neoprene or PVC. Neoprene must (1) be manufactured from a vulcanized elastomeric compound containing neoprene as the only elastomer and (2) comply with the requirements shown in the following table: Quality characteristic Test method Requirement Tensile strength (min, psi) ASTM D412 2,000 Ultimate elongation (min, %) ASTM D412 300 Compression set (max, %, 22 hours at 70 °C) ASTM D395, Method B 30 Tear strength (min, kN/m) ASTM D624, Die C 26 Hardness, Type A (points) ASTM D2240 55 ± 5 Ozone resistance (20% strain, 100 hours at 100 ± 2.2 °F) ASTM D1149 except 100 ± 20 parts per 100,000,000 No cracks Brittleness temperature at -40 °C ASTM D746, Section 9.1.2 Pass Flame propagation ASTM C542 Must not propagate flame Change in volume (max, %, IRM 903, immersed 70 hours at 100 °C) ASTM D471 80 Change in mass (max, %, immersed 7 days at 70 °C) ASTM D471 15 After accelerated aging under ASTM D573 for 70 hours at 100 degrees C, the elastomer must not show quality characteristic changes greater than those shown in the following table: Quality characteristic Requirement Tensile strength (%) -15 Elongation at break (%) -40 Hardness (points) +10 PVC waterstops must (1) be manufactured from PVC complying with CRD -C 572 and (2) comply with the ozone resistance requirement for neoprene. Furnish waterstops full length for straight portions of joints. Manufacturer's shop splices must be fully vulcanized.

51-2.04C Construction

Use spacers, wire, or other authorized methods to secure reinforcing bars supporting waterstops. If water stops are out of shape or position after placing concrete, remove the concrete and reset waterstops. Field splices for neoprene waterstops must be one of the following:

51-2.04D Payment

Not Used

51-2.05 Strip Waterstops

51-2.05A General

Section 51 -2.05 includes specifications for installing strip wa terstops .

51-2.05B Materials

The neoprene sheet must comply with the specifications for neoprene in section 51 -2.04B. The neoprene adhesive must comply with Federal Specification MMM -A-121. The protective board must be at least 1/ 2-inch-thick wood or fiberboard that is at least 4 ft long and the width shown. The neoprene sheet must be smooth and free from pin holes or surface blemishes and show no sign of delamination.

51-2.05C Construction

Join neoprene sheets as follows:

51-2.05D Payment

Not Used

51-3 Bearings

51-3.01 General

51-3.01A General

Section 51 -3 includes specifications for fabricating and installing bearings.

51-3.01B Materials

Not Used

51-3.01C Construction

Not Used

51-3.01D Payment

Not Used

51-3.02 Elastomeric Bearing Pads

51-3.02A General

51-3.02A(1) Summary

Section 51 -3.02 i ncludes specifications for fabricating and installing elastomeric bearing pads . SECTION 51 CONCRETE STRUCTURES

51-3.02A(2) Definitions

Reserved

51-3.02A(3) Submittals

51-3.02A(3)(a) General

Reserved

51-3.02A(3)(b) Samples

51-3.02A(3)(b)(i) General

Reserved

51-3.02A(3)(b)(ii) Plain Elastomeric Bearing Pads

For plain elastomeric bearing pads, the Engineer selects a test sample that is at least 8 by 12 inches from each lot of pads or batch of elastomer to be furnished, whichever results in the larger n umber of test samples. You may designate that test samples be taken at the point of manufacture or at the job site. Job site test samples are completed pads as shown. Submit plain elastomeric bearing pad test samples at least 30 days before use. Furnish additional pads to replace the pads selected for testing.

51-3.02A(3)(b)(iii) Steel -Reinforced Elastomeric Bearing Pads

Submit 1 test sample from each lot of steel -reinforced bearing pads at least 20 days before use. The size of the test sample mu st be as shown in the following table: Bearing pad thickness Test sample size 2 inches or less Smallest complete bearing shown More than 2 inches 2.25 ± 0.125 -inch-thick test sample at least 8 by 12 inches cut by the manufacturer from the center of the thickest complete bearinga aSubmit the test sample and the remaining parts of the complete bearing.

51-3.02A(3)(c) Certificate of Compliance

51-3.02A(3)(c)(i) General

Reserved

51-3.02A(3)(c)(ii) Plain Elastomeric Bearing Pads

Submit a certificate of compliance with certified test results for the elastomer for plain elastomeric bearing pads.

51-3.02A(3)(c)(iii) Steel -Reinforced Elastomeric Bearing Pads

Submit a certificate of compliance with certified test results from the bearing manuf acturer for steel - reinforced elastomeric bearing pads.

51-3.02A(4) Quality Assurance

51-3.02A(4)(a) General

Reserved

51-3.02A(4)(b) Department Acceptance

51-3.02A(4)(b)(i) General

Reserved

51-3.02A(4)(b)(ii) Plain Elastomeric Bearing Pads

The Departme nt takes specimens from the test sample, prepares them by cutting and grinding, and tests them for tensile strength, elongation, tear strength, and ozone resistance under section 51 -3.02B(2). SECTION 51 CONCRETE STRUCTURES

51-3.02A(4)(b)(iii) Steel -Reinforced Elastomeric Bearing Pads

The Department tests a specimen taken from the test sample for tensile strength, elongation, and strength under section 51 -3.02B(2). Specimens must show no loss of bond between the steel and elastomer laminates.

51-3.02B Materials

51-3.02B(1) General

Elastomeric bearing pads 1/2 inch or less in thickness must comply with section 51 -3.02B(2). Elastomeric bearing pads over 1/2 inch in thickness must comply with section s 51-3.02B(2) or 51 - 3.02B(3). Silicone grease must comply with Society of Automotive Engin eers AS 8660. Sheet metal must be commercial -quality galvanized sheet steel, smooth and free of kinks, bends, or burrs. Joints must be butt joints sealed with plastic duct -sealing tape.

51-3.02B(2) Plain Elastomeric Bearing Pads

For plain elastomeric bear ing pads, pads 1/2 inch or less in thickness must be either laminated or all elastomer. Pads over 1/2 inch in thickness must be laminated. The stacking of individually laminated pads to attain thicknesses over 1/2 inch or the cold bonding of individual lam inated pads is not allowed. Elastomeric bearing pads may be cut from large sheets. Cutting must be performed so as to avoid heating of the material, to produce a smooth edge with no tears or other jagged areas, and to cause as little damage to the material as possible. Neoprene must be the only polymer in the elastomeric compound and must be not less than 60 percent by volume of the total compound. The elastomer must comply with ASTM D4014, Type CR, Grade 3, with a shear modulus of 110 ± 10 psi. The elastom er must comply with the requirements shown in the following table: Quality characteristic Test method Requirement Tensile strength (min, psi) ASTM D412 2,250 Ultimate elongation (min, %) ASTM D412 350 Compression set (max, %, 22 hours at 70 °C) ASTM D395, Method B 25 Tear strength (min, kN/m) ASTM D624, Die C 31.5 Hardness, Type A (points) ASTM D2240 with 2 kg mass 55 ± 5 Ozone resistance (20% strain, 100 hours at 40 ± 2 °C) ASTM D1149 except 100 ± 20 parts per 100,000,000 No cracks Instantaneous thermal stiffening at -40 °C ASTM D1043 Not more than 4 times the stiffness measured at 23 °C Low temperature brittleness at -40 °C ASTM D746, Section 9.1.2 Pass After accelerated aging under ASTM D573 for 70 hours at 100 degrees C, the elastomer must not show quality characteristic changes greater than those shown in the following table: Quality characteristic Requirement Tensile strength (% loss) 15 Ultimate elongation (% loss) 40; but not less than 300 percent total elongation of the material Hardness (points) +10 SECTION 51 CONCRETE STRUCTURES

51-3.02B(3) Steel -Reinforced Elastomeric Bearing Pads

Steel -reinforced elastomeric bearing pads must comply with the specifications for steel -laminated elastomeric bearings in ASTM D4014 and the followin g:

51-3.02C Construction

Notify the Engineer of the type of bearing pad to be used b efore constructing the bearing seats. The bearing seat elevation must correspond to the selected bearing thickness. Where shown, lubricate the upper surface of the elastomeric bearing pad with a uniform film of silicone grease before placing the sheet metal cover. Do not allow grout or concrete seepage into the sliding surface during concrete placement.

51-3.02D Payment

Not Used

51-3.03 Ptfe Spherical Bearings

51-3.03A General

51-3.03A(1) Summary

Section 51 -3.03 includes specifications for fabricati ng and installing PTFE spherical bearings . PTFE spherical bearings consist of PTFE and stainless steel bearing surfaces, stainless steel plates, and anchors. PTFE spherical bearings are either (1) fixed type with spherical b earing surfaces or (2) expansion type with spherical and sliding bearing surfaces.

51-3.03A(2) Definitions

load category: PTFE spherical bearings of differing vertical load capacity within a range defined as follows:

51-3.03A(3) Submittals

51-3.03A(3)(a) General

Submit proof that the bearing manufacturer has furnished PTFE spherical bearings that have had at least 3 years of satisfactory service for 2 projects with similar conditions to this project. Submit certificates of compliance for the materials used in PTFE bearings. Submit test reports for proof -tested bearings signed by the personnel conducting the testing. Include bearing numbers of the tested bearings and the names of the personnel interpreti ng the test results. If proof tests cannot be performed at the specified load, submit a testing plan listing additional physical tests to be performed. SECTION 51 CONCRETE STRUCTURES

51-3.03A(3)(b) Shop Drawings

Submit shop drawings electronically to sc.office.associates@dot.ca.gov . Allow 55 days for the Department’s review for railway bridges and at least 45 days for all other st ructures. Shop drawings must include a description of the method of mechanical interlocking of PTFE fabric to the metallic substrate . At locations other than hinges, shop drawings must include temporary support details for the bearing sole plate during concrete placement.

51-3.03A(4) Quality Assurance

51-3.03A(4)(a) General

The bearing manufacturer must have furnished PTFE spherical bearings that have had at least 3 years of satisfactory service for 2 projects with similar conditions to this pro ject. A qualified representative of the bearing manufacturer must be present during installation of the 1st bearing and be available during remaining installations. Templates for the spherical surfaces must be available for inspection.

51-3.03A(4)(b) Qual ity Control

51-3.03A(4)(b)(i) General

Reserved

51-3.03A(4)(b)(ii) Proof Testing

Proof test the PTFE spherical bearings in the Engineer's presence as follows:

51-3.03B Materials

51-3.03B(1) General

Welding must comply with AWS D1.1 except welding of stainless steel must comply with AWS D1.6. PTFE spherical bearings must be self -lubricating. PTFE surfaces must be unfilled fabric made from virgin PTFE oriented multifilament and other fibers. Filament resin must comply with ASTM D4441. At the highest point of substrate and after compression, the PTFE fabric must have a thickness from 1/16 to 1/8 inch . Steel plates must comply with ASTM A709/A709M. Stainless steel plates must comply with ASTM A240/A240M, Type 304, and be at least 1/8 inch thick. Surfaces of flat stainless steel that mate with PTFE surfacing must have a minimum no. 8 mirror finish. Surfaces of curved stainless steel that mate with PTFE surfacing must have a finish of less than 16 microinches root mean square. Determine the finish under ANSI B46.1. PTFE spherical bearings must have an initial static coefficient of friction of at most 0.06 . Stud connectors must comply with section 55 -1.02. Protect bearing surfaces from contamination and weather damage.

51-3.03B(2) Fabrication

Flat stainless steel surfaces must be a weld overlay on structural steel plate or a solid or sheet stainless steel. Curved stainless steel surfaces must be solid stainless steel except curved stainless steel surfaces over 6 inches thick may be a weld overlay on structural steel plate. If a weld overlay is used for stainless steel surfacing, attach the overlay by submer ged arc welding using Type 309L electrodes. The completed overlay must have a 3/32 -inch minimum thickness after fabrication. If stainless steel sheets are used for stainless steel surfacing, attach the sheets by perimeter arc welding using Type 309L electr odes. After welding, the stainless steel surface must be smooth and without waves. Plate radius dimensional tolerances are from 0.000 to -0.010 inch for convex plates and from +0.010 to 0.000 inch for concave plates. Use full -size convex and concave metal templates for the spherical surfaces of each bearing radius. PTFE fabric backing material on bearing surfaces must be epoxy bonded and mechanically interlocked to the steel substrate. Bonding must be performed under controlled factory conditions. The mechanical interlock on the spherical concave surface must be integrally machined into the steel substrate. Welded retention grids are not allowed on the concave surface. Except for the selvage, oversaw or recess edges such that no cut fabric edges are ex posed. During fabrication, the maximum temperature of bonded PTFE surfaces must be 300 degrees F. SECTION 51 CONCRETE STRUCTURES After bonding to the substrate, the PTFE surface must be smooth and free from bubbles. Assemble PTFE spherical bearings at the fabrication site. The PTFE and stainless steel interfaces must be in full bearing after completing assembly. Use at least 4 steel straps bolted to threaded holes in the masonry and sole plates to secure each bearing assembly as a unit for shipment. Steel straps must (1) not be welded an d (2) be adequate to use for lifting the bearing assembly. Bearings must be shipped as a unit and remain intact when uncrated and installed.

51-3.03C Construction

Prepare concrete surfaces to receive PTFE spherical bearings under section 55 -1.03C(3). The Engineer must be present during the dismantling of each bearing assembly at the job site. Temporarily support PTFE bearing sole plates during concrete placement. Temporary supports must prevent rotation or displacement of the bearings. Temporary supports m ust not (1) inhibit the function of the PTFE bearings after concrete is placed or (2) restrict movement at bridge joints due to temperature changes and prestress shortening. Materials for temporary supports must comply with the requirements for form fasten ers in section 51 -1.03C(2)(a). Replace or resurface damaged bearings and bearings with scratched mating surfaces. Resurfacing must be performed at the bearing manufacturer's plant.

51-3.03D Payment

The payment quantity for PTFE spherical bearings does not include the test bearings. A PTFE spherical bearing with more than 1 PTFE surface is 1 bearing.

51-3.04 51-3.05 Reserved

51-4 Precast Concrete Members

51-4.01 General

51-4.01A Summary

Section 51 -4 includes specifications for constructing precast concr ete members . Prestressing concrete members must comply with section 50. Cure PC concrete members under section 90 -4.03. Furnishing PC concrete members includes furnishing members to the job site ready to incorporate into the work. Erecting PC concrete members includes erecting members into final position in the work.

51-4.01B Definitions

Reserved

51-4.01C Submittals

51-4.01C(1) General

Submit a certificate of compliance signed by the manufacturer's QC representative for each PC concrete box culvert shipment. For PC PS concrete girders and deck panels, submit an erection work plan. The work plan must be signed by an e ngineer who is registered as a civil engineer in the State and include procedures, details, and sequences for:

51-4.01C(2) Shop Drawings

51-4.01C(2)(a ) General

Submit shop drawings for PC concrete members electronically to sc.off ice.associates@dot.ca.gov . For drainage inlets with oval or circular cross sections, submit shop drawings with calculations. Shop drawings and calculations must be sealed and signed by an engineer who is registered as a civil engineer in the State. Allow 15 days for the Engineer's review.

51-4.01C(2)(b) Girders

For PC PS concrete girders, shop drawings must include:

51-4.01C(2)(c) Closure Wall Panels

Submit 2 copies of shop drawings for PC concrete closure wall panels as an informational submittal. Include in the submittal:

51-4.01C(2)(d) Box Culverts

Shop drawings for PC concrete box culverts must include the construction method, dimensions, reinforcement including splice type and location, and height of earth cover.

51-4.01C(2)(e) Deck Panels

For PC deck panels, shop drawings must include:

51-4.01D Quality Assurance

51-4.01D(1) General

PC materials must be available to the Department for inspection. Allow the Department free access at all times to any portion of the fabrication site where material is stored or work is performed.

51-4.01D(2) Quality Control

Reserved

51-4.01D(3) Department Acceptance

PC concrete members are inspected at the fabrication site. Notify the Department when materials are delivered to the fabrication site. Allow 10 days after notifying the Dep artment before starting fabrication. The Engineer may reject PC drainage inlets exhibiting any of the following:

51-4.02 Materials

51-4.02A General

Reserved

51-4.02B Delivery, Storage, and Handling

Carefully handle, store, transport, and erect PC concrete members to avoid twisting, racking, or other distortion that would result in cracking or damage to the members . Handle, store, transport, and erect PC members in a position such that the points of support and directions of the reactions with respect to the member are approximately the same as when the member is in its final position.

51-4.02C Materials

For a proj ect in a freeze -thaw area, reinforcement must be epoxy coated under section 52 -2.02. Bearing plates, threaded inserts, and other metal fittings must comply with section 75 -3 Concrete for keyways must have a cementitious material content of at least 590 lb/cu yd and a 1 -inch maximum grading. Penetration of the concrete must be near the lower limit of the specified nominal penetration. Grout mus t comply with ASTM C1107/C1107M. Deck shear connector rods, shown as tie rods, must comply with the following:

51-4.02D Fabricating Precast Concrete Members

51-4.02D(1) General

Reserved

51-4.02D(2) Girders, Box Girders, and Double T Girders

Before curing activities, the top surface of each PC member must be given a coarse texture by brooming with a stiff bristled broom or by other suitable devices that results in uniform transverse scoring. The top surface texture of the following PC members m ust have at least a 1/4 -inch amplitude:

51-4.02D(3) Slabs

Forms for circular voids in concrete slabs must (1) be watertight and constructed of an authorized material that does not break or deform during concrete placement and (2) not increase the span dead load. Before curing, the top surface o f concrete slabs must be given a coarse texture by brooming with a stiff - bristled broom or by other suitable devices that results in uniform transverse scoring. The requirements of the 8th and 9th paragraphs of section 51 -1.01D(3)(b)(ii) do not apply.

51-4.02D(4) Closure Wall Panels

Exposed surfaces of closure wall panels must match the adjacent CIP concrete. Prestressing steel must be (1) placed not more than 6 inches from panel edges and (2) spaced not more than 18 inches on center between edge tendons. Anchorage hardware must comply with section 75 -3. Bolt holes must comply with section 55 -1.02E(6)(b) except holes must not be punched or plasma cut full size.

51-4.02D(5) Box Culverts

Reinforcement for PC concrete box culverts may be welded wire reinforce ment. Manufacturing tolerances for PC sections must comply with the tolerances specified in section 11 of AASHTO M 259. You may use the dry cast method of construction where shown on the authorized shop drawings. Results must be equal to those obtained und er section 51. External vibrators must be used. Forms must be sufficiently rigid to resist displacement or damage. Dry casting forms may be removed after consolidating if no slumping of the concrete occurs. Form the ends of members such that sections can b e laid together to make a continuous line of box sections with a smooth interior free of irregularities in the flow line. SECTION 51 CONCRETE STRUCTURES Splices in circumferential reinforcement must be lapped. Welded splices for the outside apron of steel are allowed only where shown. W all reinforcement on the inside of the box may be lapped and welded at any location or connected by welding at the corners to slab reinforcement at the inside of the box. Handling devices or holes are allowed in members for handling and laying. Clean and f ill the resulting holes with mortar. Exposed spacers, standoffs, or ends of longitudinals used to position reinforcement are not a cause for rejection. Do not weld spacers or standoffs to circumferential reinforcement. You may weld spacers or standoffs to longitudinal reinforcement. Clearly mark each PC unit. Use indentation, waterproof paint, or other authorized means. Include contract number, date of manufacture, manufacturer, and the design earth cover. Mark each unit by indentation on the inner or outer surface so that the top is evident immediately after stripping forms. Paint the word "TOP" with waterproof paint on the inside and outside surfaces of the tops of each unit.

51-4.02D(6) Lagging

For a project in a freeze -thaw area, concrete for PC concret e lagging must contain at least 675 pounds of cementitious material per cubic yard. If concrete lagging is steam cured, supports for reinfor cement must be stainless steel containing at least 16 percent chromium.

51-4.02D(7) Deck Panels

Clearly label the top surface of each panel with the word TOP as shown on the deck panel layout using waterproof paint or other authorized means. Apply a coars e texture to at least 90 percent of the deck panel top surface area by brooming with a stiff bristled broom or by other suitable devices that results in uniform scoring parallel with the prestressing strands. The top surface texture must have a maximum 1/8 -inch texture. Each camber strip must:

51-4.02D(8) Drainage Inlets

PC units for drainage inlets must be rectangular, round, or oval in cross section, or any combination. Transitions from a rectangular grate opening to a round or oval basin must be made in not less than 8 inches. Provide means for field adjustment to meet final grade, paving, or surfacing. If oval or circular shape cross -sections are furnished , they must comply with AASHTO LRFD Bridge Design Specifications, Sixth Edition with California Amendments . Wall and slab thicknesses may be less than the dimensions shown by at most 5 percent or 3/16 inch, whichever is greater. SECTION 51 CONCRETE STRUCTURES Reinforcement placement mus t not vary more than 1/2 inch from the positions shown.

51-4.03 Construction

51-4.03A General

Reserved

51-4.03B Girders, Box Girders, and Double T Girders

For girders and box girders or double T girders with a concrete deck shown, clean top surfaces of laitance and curing compound before placing deck concrete. You may make adjustments to accommodate girder deflections before placing deck concrete, including adjustments to bearing seat elevations. Adjustments are limited by the following:

51-4.03C Slabs

For slab spans with a concrete overlay, clean the slab top surfaces under section 51 -1.03D(4). For slab spans with an HMA overlay, removal of laitance and curing compound from the top surfaces is not required. Where the ends of transverse rods will be exposed, recess exposed nuts and ends of rods at least 1 inch below the member surface. Snug tighten nuts after the deck units are positioned and before placing mortar in the keyways. Fill the anchor dowel holes with mortar after the slabs are in final position. Fill keyways with concrete. Keyways must be mortar -tight before placing concrete. Thoroughly consolidate the concrete in keyways. Tighten nuts 24 hours after concrete in the keyways has been placed. Burr threads at the ends of bolts or rods to prevent loosening. Fill recesses with mortar after tightening nuts. SECTION 51 CONCRETE STRUCTURES No equipment or other loads are allowed on spans until 72 hours after the last mortar is placed in anchor dowel holes or the last concrete is placed in keyways. For slab spans with a concrete overlay, at least 3 slabs adjacent to a span must be in place before the concrete overlay is placed in that span.

51-4.03D Closure Wall Panels

Reserved

51-4.03E Box Culverts

Construct box culverts using P C members where described. You must select the combination of concrete dimensions and reinforcement if more than 1 allowable combination is shown. Structure excavation and backfill must comply with section 19 -3. Laying of PC concrete box culverts must comp ly with the specifications for laying reinforced concrete pipe in section 65 -2.03C. Joints must comply with the specifications for cement mortar or resilient material joints in section 65 - 2.02F. You may use an external sealing band complying with ASTM C877 instead of joint material.

51-4.03F Lagging

Place concrete lagging for soldier piles walls level. Place a concrete leveling course if required. Each lagging member must be continuous over 2 piles and cantilever at least 6 inches beyond pile centerlines. Continuity over 3 piles is not allowed.

51-4.03G Deck Panels

Construct the deck panel system in the following sequence:

51-4.03H Drainage Inlets

Repair PC drainage inlet sections to correct damage from handling or manufacturing imperfections before installation. Center pipes in openings to provide a uniform gap. Seal gaps between the pipe and the inlet opening with nonshrink grout under the grout manufacturer's instructions. For systems designated as watertight, seal these gaps with resilient connectors. SECTION 51 CONCRETE STRUCTURES Match fit keyed joints to ensure uniform alignment of walls and lids. Keys are no t required at the inlet floor level if the floor is precast integrally with the inlet wall. Seal keyed joint locations with preformed butyl rubber joint sealant. You may seal the upper lid and wall joint with nonshrink grout. Clean keyed joint surfaces bef ore installing sealant. Joint surfaces must be free of imperfections that may affect the joint. Use a primer if surface moisture is present. Use a sealant size recommended by the sealant manufacturer. Set joints using sealant to create a uniform bearing su rface. Flat drainage inlet floors must have a field -cast topping layer at least 2 inches thick with a slope of 4:1 (horizontal:vertical) toward the outlet. Use a bonding agent when placing the topping layer. Apply the bonding agent under the manufacturer's instructions.

51-4.04 Payment

Payment for diaphragm dowels and bolts in PC concrete members is not included in the payment for any type of furnish or erect PC concrete member. The payment quantity for PC concrete lagging is the wall area shown without de ductions for spacing between lagging or openings for piping. PC concrete box culvert is measured as specified for concrete pipe in section 65 -1.04.

51-5 Approach Slabs

51-5.01 General

51-5.01A Summary

Section 51 -5 includes specifications for constructin g approach slabs and paving notch extensions. Structure approach drainage system must (1) consist of geocomposite drain, filter fabric, plastic pipe, treated permeable base, and drainage pa ds, and (2) comply with section 68 -7. Structure excavation and backfill must comply with section 19 -3. Treated permeable base must comply with section 29.

51-5.01B Definitions

Reserved

51-5.01C Submittals

If using RSC, submit the RSC mix design at least 10 days before constructing the trial slab.

51-5.01D Quality Assurance

51-5.01D(1) General

If woven tape fabric is shown, notify the Engineer of the source of woven tape fabric at least 45 days before use. Notify the Engineer of the type of treated permeable base to be used under approach slabs at least 30 days before starting placement. After notification, do not change the type of permeable base without authorization.

51-5.01D(2) Quality Control

51-5.01D(2)(a) General

Reserved

51-5.01D(2) (b) Rapid Strength Concrete

Before starting work on approach slabs constructed using RSC , prepare a trial slab for each concrete mix design. Trial slabs must be:

51-5.02 Materials

51-5.02A General

Hardboard and expanded polystyrene must comply with section 51 -2.01B(1).

51-5.02B Fabric

Filter fabric must be Class A. Woven tape fabric must:

51-5.02C Concrete

Concrete for approach slabs and paving notch extensions must con tain at least 675 pounds of cementitious material per cubic yard and comply with one of the following:

51-5.02D Aggregate Base

AB must be produced from commercial -quality aggregates consisting of broken stone, crushed gravel or natural rough -surfaced gravel, and sand, in any combination. Gradation must comply with the 3/4 -inch maximum gradation specified in section 26 -1.02B.

51-5.02E Bar Reinforcement

Bar reinforcing steel must comply with section 52. In a freeze -thaw area, epoxy coat bar reinforcement under section 52 -2.02. Galvanize unbonded portions of bar reinforcement under section 52 -3.

51-5.02F Miscellaneous Joint Materials

Steel components of abutment ties mus t comply with section 75 -1. PVC conduit used to encase abutment tie rods must be commercial quality. Steel angles, plates, and bars at concrete barrier joints must comply with section 75 -1. Type AL joint seals must comply with section 51 -2.02B. The pourable seal between the steel angle and concrete barrier must comply with the specifications for Type A and AL joint seals in section 51 -2.02B. Sealants may be mixed by hand -held, power -driven agitators and placed by hand methods. Sliding joints for the sleeper slabs must comply with 51 -2.03. Building paper must be commercial -quality, 30 -pound asphalt felt.

51-5.02G Hot Mix Asphalt

HMA for a temporary roadway structural section must comply with the specifications for minor HMA in section 39.

51-5.03 Con Struction

51-5.03A General

Drill and bond bar reinforcement and abutment tie rods under section 51 -1.03E(3). Finish and treat the top surfaces of approach slabs under section 51 -1.03F(5). Edger finish the slab edges. Cure approach slabs using curing compo und no. 1. Abrasive blast clean the concrete surfaces and thoroughly clean joints immediately before placing the joint seals. Joint surfaces must be dry when seals are placed.

51-5.03B Type N Approach Slabs

51-5.03B(1) General

Reserved

51-5.03B(2) Filter Fabric

Place filter fabric immediately after grading and compacting the subgrade. Handle and place filter fabric under the manufacturer's instructions. Adjacent borders of filter fabric must be overlapped from 12 to 18 inche s or stitched. If overlapping the borders, the preceding roll must overlap the following roll in the direction the material is being spread. If stitching the border, use yarn of a contrasting color. Yarn size and composition must be as recommended by the f abric manufacturer. Use 5 to 7 stitches per inch of seam. Do not operate equipment or vehicles on filter fabric. SECTION 51 CONCRETE STRUCTURES

51-5.03B(3) Treated Permeable Base

Place and compact ATPB at a temperature from 200 to 250 degrees F. Do not use material stored for more than 2 hours in the work. Compact ATPB base as soon as the mixture has cooled sufficiently to support the weight of the equipment without undue displacements. Use a vibrating -shoe -type compactor or a roller weighing from 1.5 to 5 tons. Compact CTPB with a vibr ating -shoe -type compactor or with a steel -drum roller weighing from 1.5 to 5 tons. Compaction must start within 1/2 hour of spreading and must consist of 2 complete coverages of the CTPB.

51-5.03C Type EQ Approach Slabs

Reserved

51-5.03D Type R Approach Slabs

51-5.03D(1) General

The Type R approach slab thicknesses shown are minimums. Thicknesses may vary due to material removed. At locations where the removal of existing materials and approach slab construction is not required to be completed within the same work shift, the requirements for a temporary roadway structural section and trial slab do not apply. Approach slab (aggregate base) includes using AB to fill voids that remain after removing subsealing material or C TB beneath existing approach slabs.

51-5.03D(2) Removal of Existing Facilities

Remove portions of existing structures, pavement and base, approach slabs, asphalt concrete surfacing, concrete pavement, subsealing material, and cement -treated base, as neces sary for the construction of the new approach slab. Remove portions of seat -type abutments under section 60 -2.02. Saw cut full depth the outline of concrete pavement to be removed using a power -driven saw. Do not use power impact tools within 1.5 feet of p avement to remain in place. Before removing asphalt concrete, cut the outlines of excavations in asphalt concrete on a neat line to a minimum depth of 0.25 foot using a power -driven concrete saw or wheel -type rock -cutting excavator. These excavations must be permanently or temporarily backfilled to conform to the grade of the adjacent pavement before opening the lane to traffic. Dispose of materials no longer used in the work.

51-5.03D(3) Existing Base Material

Uniformly grade and compact the existing base material remaining in place after removing the existing pavement and base materials to the required depth. The finished surface of the base material at any point must not extend above the authorized grade. Fill areas of base material that are low as a res ult of overexcavation with structure approach slab concrete at the same time that the new concrete is placed. Where pavement subsealing has been performed under existing approach slabs, remove the full depth of subsealing material. Where removal of CTB is required to construct the approach slab, remove the full depth of the CTB. Fill voids between the new approach slab and the base material remaining in place that are caused by removal of subsealing material or CTB with either AB or approach slab concrete. If you fill these voids with structure approach slab concrete, fill the voids at the same time that the new concrete is placed. SECTION 51 CONCRETE STRUCTURES

51-5.03D(4) Aggregate Base

Spread and compact AB for filling voids below the structure approach slab concrete by methods that w ill produce a well -compacted, uniform base, free from pockets of coarse or fine material, to the authorized grade. Where the required thickness of AB is 8 inches or less, the base may be spread and compacted in 1 layer. Where the required thickness of AB i s more than 8 inches, the base must be spread and compacted in 2 or more layers of approximately equal thickness. The maximum compacted thickness of any 1 layer must not exceed 8 inches.

51-5.03D(5) Profile Grade

Establish a grade line for the new approac h slab that will provide a smooth profile grade. The profile grade must be authorized.

51-5.03D(6) Temporary Roadway Structural Section

If approach slabs cannot be constructed before the lane is opened to traffic, fill the excavation with a temporary road way structural section. Temporary structural section must consist of a 0.3 -foot-thick layer of commercial quality cold mix over AB. Keep a standby quantity of cold mix and AB at the job site for a temporary roadway structural section. Spread and compact th e AB and cold mix. Produce a well -compacted, uniform base having a surface of uniform smoothness, texture, and density, without pockets of coarse or fine material. You may spread and compact AB and cold mix in 1 layer each. The finished surface (1) must no t vary more than 0.05 foot from the lower edge of a 12 -foot straightedge placed parallel with the centerline and (2) must match the elevation of the existing pavement and structure along the joints between the existing pavement and structure and the tempor ary surfacing. Maintain the temporary structural section until it is replaced with the approach slab.

51-5.03E Paving Notch Extensions

The construction joint between the paving notch extension and the existing abutment must comply with the specifications for horizontal construction joints in section 51 -1.03D(4). Patch spalls in the existing paving notch when placing the paving notch extension. The surface temperature must be at least 40 degrees F during concrete placement. Co ntact surfaces to receive concrete may be damp but not saturated. Retempering of concrete is not allowed. Finishing tools cleaned with water must be thoroughly dried before working concrete. The Engineer may require you to use a flow-controlled modified material when placing concrete on slopes over 5 percent. Except for magnesium phosphate concrete, cure the concrete using the curing compound method. Allow 12 hours between placing the paving notch extension and placing the approac h slab. If using magnesium phosphate concrete, modified high -alumina -based concrete, or portland -cement - based concrete complying with section 51 -1.02C to construct the paving notch extension, allow 1 hour between placing the paving notch extension concrete and placing the approach slab concrete. If using RSC to construct the paving notch extension, the RSC must have a minimum compressive strength of 1,200 psi before placing the approach slab concrete and a minimum compressive strength of 2,500 psi before op ening the overlaying approach slab to traffic.

51-5.04 Payment

The payment quantity of aggregate base (approach slab) is the volume used to fill voids below approach slab concrete. The payment quantity does not include the volume of AB used to fill an ove rexcavation . Structural concrete used to fill voids below the approach slab that are caused by removal of subsealing material or CTB is paid for as aggregate base (approach slab). The payment quantity does not include the volume of structure concrete used to fill an overexcavation. SECTION 51 CONCRETE STRUCTURES

51-6 Mass Concrete

51-6.01 General

51-6.01A Summary

Section 51 -6 includes specifications for placing mass concrete elements.

51-6.01B Definitions

Reserved

51-6.01C Submittals

Submit a thermal control pl an with design calculations for each mass concrete element. The thermal control plan and the calculations must be sealed and signed by an engineer who is registered as a civil engineer in the State. Submit 6 copies of the control plan and 2 copies of the d esign calculations. Include the following:

51-6.01D Quality Assurance

51-6.01D(1) General

An engineer who is registered as a civil engineer in the State must:

51-6.01D(2) Quality Control

51-6.01D(2)(a) General

Reserved

51-6.01D(2)(b) Temperature Monitoring

Provide a temperature monitoring and recording system for mass concrete elements. The system must consist of temperature sensors connected to a data acquisi tion system. The system must be capable of recording, printing, and downloading temperature data to a computer. Locate temperature sensors within mass concrete elements such that the maximum temperature difference within the element is monitored. At a mini mum, monitor temperatures at the following locations:

51-6.02 Materials

Grout for cooling pipes must be a nonshrink grout mix complying with ASTM C1107/C1107M and ASTM C827/C827M for 0.0 percent shrinka ge and 0.0 percent minimum and 4.0 percent maximum expansion.

51-6.03 Construction

You may use mechanical cooling systems to control internal concrete temperatures during curing. Mechanical cooling systems must comply with the thermal control plan. Embed the cooling system within the mass concrete element. Surface connections to cooling pipes must be removable to 4 inches below the concrete surface. Design the forms such that cooling or temperature monitoring is not disturbed during form removal. Secure th e cooling pipes to prevent movement during concrete placement. Replace damaged cooling pipes immediately. Pressure test the cooling system for leaks at 30 psi for 30 minutes before placing concrete. Coolant must be circulating when concrete placement start s. Pressure grout the cooling pipes after cooling is complete. Place the grout under the manufacturer's instructions. After the surface connections are removed, the holes must be reamed and filled with mortar. Remove mass concrete elements that do not comp ly with the temperature acceptance criteria.

51-6.04 Payment

Not Used

51-7 Minor Structures

51-7.01 General

Section 51 -7 includes specifications for constructing minor structures . Minor structures include structures described as minor structures.

51-7.02 Materials

Concrete must comply with the specifications for minor concrete. Nonshrink grout must be a dry, packaged type complying with ASTM C1107/C1107M. SECTION 51 CONCRETE STRUCTURES Metal frames, covers, grates, and other miscellaneous iron and steel used with minor structures must comply with section 75 -2.

51-7.03 Construction

You may construct minor structures using PC units or a combination of PC and CIP structures as an alternative to CIP construction, provided that the structure in place substant ially complies with the specified CIP construction. Remove exterior forms to at least 5 inches below the final ground surface. Exterior forms below this depth may remain if their total thickness is not more than 1 inch. Cure concrete surfaces of minor stru ctures using the water method, the forms -in-place method, or the curing compound method.

51-7.04 Payment

The Department does not adjust the payment quantity for minor structures designated as final pay on the Bid Item List if the constructed height of the minor structure is within 6 inches of the vertical dimensions shown. Metal frames and covers or frames and grates are not included in the payment for minor structures.

51-8 Hinge Transverse Shear Key

51-8.01 General

Section 51 -8 includes specifications for fabricating hinge transverse shear keys.

51-8.02 Materials

Hinge transverse shear keys must consist of HSS tubular section, HS threaded rods, nuts, washers, angles, mechanical expansion anchors, building paper, polyethylene, and thread -locking system. HSS tubular section must comply with the specifications for steel structural tubing in section 55 -1.02D(1) . HS threaded rods, nuts, and washers must comply with section 55 -1.02D(1). Angles must comply with section 55 -1.02D(3). Mechanical expansion anchors must comply with section 75 -3.02C. Building paper must be commercial -quality, 30 -pound asphalt felt. Polyethylene must have a compressive strength of at least 10 psi with a deflection between 5 percent and 15 percent when tested under ASTM D3575, Suffix B . Thread -locking systems must comply with section 75 -3.02B. Galvanize under section 75 -1.02B. After galvanizing, alterations resulting in new exposed surfaces, including holes or cut ends, must be coated as specified for repairing damaged galvanized surfac es under section 75 -1.02B.

51-8.03 Construction

Not Used

51-8.04 Payment

Not Used

51-9 51-15 Reserved