60 EXISTING STRUCTURES
60-1 General
60-1.01 General
Section 60 includes specifications for performing work on existing structures .
60-1.02 Materials
Not Used
60-1.03 Construction
Not Used
60-1.04 Payment
Not Used
60-2 Structure Removal
60-2.01 General
60-2.01A General
Section 60 -2.01 includes general specifications for removing structures or portions of structures. Design and construct temporary support shoring, temporary bracing, and protective covers under section 48. Temporary supports must comply with section 48 -3.
60-2.01B Materials
Not Used
60-2.01C Construction
Before removing portions of monolithic concrete elements, make a 1 -inch-deep saw cut to a true line along the limits of removal on faces of the element that will be visible in the completed work. Remove piling, piers, abutments, footings, and pedestals to 1 foot below the ground line or 3 feet below finished grade, whichever is lower. Protect existing reinforcement to be incorporated into the new work from damage. Thoroughly remove all material adhering to the existing reinforcement before embedding the exi sting reinforcement in new concrete. Do not use explosives. Do not use the following for breaking or removing concrete attached to or supported by bridges:
1.Tools with a manufacturer's -rated striking energy of more than 1,200 ft -lb per blow
2.Freely fal ling mass
3.Falling mass attached to a cable, rope, or chain Do not use a freely falling mass or a falling mass attached to a cable, rope, or chain above any public space. Do not use falling masses within 30 feet horizontally of any public space without protective covers. Design and construct protective covers, shoring, and falsework with sufficient strength and rigidity to support all imposed loads. Covers must be at least equal to 2 -inch Douglas -fir planking on posts spaced at 5-foot centers . The Engine er may require you to remove existing footing concrete that is below ground and outside of the footing limits. This work is change order work.
60-2.01D Payment
Not Used SECTION 60 EXISTING STRUCTURES
60-2.02 Bridge Removal
60-2.02A General
60-2.02A(1) Summary
Section 60 -2.02 include s specifications for removing bridges or portions of bridges.
60-2.02A(2) Definitions
Reserved
60-2.02A(3) Submittals
If a daily removal report is required, submit the daily removal report as an informational submittal. Submit the daily report by close of business on the following business day. Submit a bridge removal work plan for each bridge. Include details for the following:
1.Removal sequence, including staging of removal activi ties and equipment locations
2.Temporary supports or bracing
3.Locations where work is performed over traffic, utilities, or railroad property
4.Locations and types of protective covers
5.Protection of people, property, utilities, and improvements
6.Methods for preventing material, equipment, and debris from falling onto traffic or railroad property If protective covers are required or superstructure removal work is performed, bridge removal work plans must be (1) accompanied by substantiating calcula tions and (2) signed by an engineer who is registered as a civil engineer in the State. Calculations for bridge removal work plans must demonstrate the stability of the structure during each stage of removal and must include dead and live loads used in the design of the protective covers. A stage is removal of (1) the deck, soffit, or girders in any span; or (2) walls, bent caps, or columns at support locations. Allow 20 days for review of the bridge removal work plan.
60-2.02A(4) Quality Assurance
60-2.02A(4)(a) General
Reserved
60-2.02A(4)(b) Preconstruction Meeting
Schedule and hold a preconstruction meeting for bridge removal. The following personnel must attend the preconstruction meeting with the Engineer:
1.Contractor
2.Engineer of Record for bri dge removal work plan
3.Demolition subcontractor if applicable
4.Railroad representative if applicable The Engineer conducts the meeting. Be prepared to discuss:
1.Authorized bridge removal work plans
2.Key contact persons and phone numbers
3.Coordination with lane closures, Traffic Operations, and Construction Zone Enhanced Enforcement Program
4.Equipment used for bridge removal work
5.Removal of any utilities
6.Removal of any items to be salvaged and stored
7.Debris containment and collec tion plan
8.Personal protective equipment
9.Hazardous material handling, storage, and removal
10.Protocol for handling unexpected conditions
11.Protecting adjacent facilities and utilities SECTION 60 EXISTING STRUCTURES
12.Lane closure schedule if applicable
13.Contingency plan if applicable
60-2.02A(4)(c) Quality Control
For bridge removal work plans signed by a registered engineer, the Engineer signing the work plan must confirm the conditions at least 1 business day before the start of bridge removal activities by visual inspe ction. Discuss the condition of the structure with the Contractor's project superintendent and the Engineer at the site. For bridge removal activities, the Engineer signing the work plan must:
1.Be registered as a civil engineer in the State.
2.Have expe rience in bridge removal plan design or bridge removal construction inspection.
3.Be present at all times during bridge removal activities.
4.Ensure compliance with the authorized work plan.
5.Stop the operation if it is unsafe. Before resuming operatio ns, submit a proposed revision to the authorized work plan to remedy the unplanned occurrence.
6.Prepare a daily removal report for removal activities. The report must describe work activities for each day and the condition of the remaining structure. The report must be sealed and signed by an engineer who is registered as a civil engineer in the State. The engineer signing the work plan may assign a representative to perform the bridge removal activities specified above. The engineer signing the work pla n must submit a letter that is sealed and signed certifying that the representative:
1.Is registered as a civil engineer in the State
2.Has experience in bridge removal plan design or bridge removal construction inspection
3.Is familiar with the authori zed work plan
4.Will attend at least 1 job site visit with the Contractor's project superintendent and the Engineer to discuss the authorized work plan at least 1 business day before beginning the bridge removal activities
60-2.02B Materials
Design criteria for temporary support shoring and temporary bracing must comply with section 48 -3.02B.
60-2.02C Construction
60-2.02C(1) General
The Engineer may require you to perform additional exploratory work of bridge members for unforeseen damage. This work is change order work. You may use flame and saw cutting for removing, widening, or modifying bridges. If complete bridges are removed, do not start removal activities until traffic is no longer carried on the bridge. For bridge removal activities over or adjacent to roadways that are only closed to traffic when removal work is being performed:
1.Have all necessary personnel, materials, and equipment to complete the work onsite before closing the roadway. Perform activities without interruption un til the roadway is reopened.
2.Perform bridge removal activities only when the roadway is closed to traffic except as specified for preliminary work.
3.During roadway closures, debris from bridge removal activities may fall directly onto the roadway if protection is furnished for highway facilities. Minimum protection for paved areas is a 2 -foot-thick earthen pad or a 1 -inch-thick steel plate placed over the impact area. Before reopening the roadway, all debris, protective pads, and devices must be remove d and the roadway swept clean with wet power sweepers or equivalent methods.
4.For girder bridges, completely remove each girder within a span before starting removal of the adjacent girder. SECTION 60 EXISTING STRUCTURES
5.For slab bridges, perform removal activities within a span al ong a front parallel with the primary reinforcing steel. Temporary support shoring, temporary bracing, and protective covers must not encroach within 8 feet horizontally or 15 feet vertically of traffic lanes or shoulders open to traffic. Temporary suppor t shoring, temporary bracing, and protective covers over railroad property must (1) conform to guidelines of the railroad company involved and (2) provide the minimum clearances specified for railroad traffic.
60-2.02C(2) Protective Covers
Provide protect ive covers for removal work over traffic or railroad property. Protective covers must:
1.Be constructed before starting removal activities.
2.Prevent a ny materials, equipment, or debris from falling onto traffic or railroad property.
3.Be supported using shoring, falsework, or the existing structure.
4.Provide the openings specified in section 12 -4. If no openings are specified for removal work, provid e a vertical opening of 15 feet and a horizontal opening of 32 feet for traffic.
5.Be cleaned of debris and fines before being removed. At locations where only bridge railing is removed, protective covers must extend from the face of the exterior girder or at least 2 feet inside of the railing to be removed to at least 4 feet beyond the outside face of the railing. At locations where entire girders are removed, protective covers must extend at least 10 feet beyond the outside face of the bridge railing. A separate protective cover is not required during removal of bridge segments if portions of the bridge satisfy the requirements for protective covers.
60-2.02C(3) Preliminary Work
Preliminary work is limited to activities that (1) will not reduce the str uctural strength or stability of the bridge or bridge elements to a hazardous level as determined by the Engineer or (2) do not cause debris or any other material to fall onto the roadway. You may perform preliminary work if you use protective covers. Prot ective covers must:
1.Support all loads
2.Prevent dust and fine material from falling onto the traveled way
3.Extend at least 4 feet beyond the limit of the work being performed Bottom slabs of box girders may be considered as protective covers for pre liminary work performed on top slabs inside the limits of the exterior girders. Use temporary support shoring and bracing during preliminary work if needed to ensure the stability of the bridge.
60-2.02D Payment
Not Used
60-2.03 60-2.10 Reserved
60-3 Structure Rehabilitation
60-3.01 General
60-3.01A General
Section 60 -3.01 includes general specifications for rehabilitating structures . If you are unable to complete bridg e 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. Where shown, (1) repair and prepare surfaces and (2) apply deck treatments and o verlays to approach slabs as specified for concrete bridge deck surfaces. SECTION 60 EXISTING STRUCTURES
60-3.01B Materials
Not Used
60-3.01C Construction
Not Used
60-3.01D Payment
Not Used
60-3.02 Bridge Deck Repair and Preparation
60-3.02A General
60-3.02A(1) Summary
Section 60-3.02 includes specifications for (1) repairing concrete deck surfaces and (2) preparing concrete deck surfaces to receive an overlay or a deck treatment.
60-3.02A(2) Definitions
Reserved
60-3.02A(3) Submittals
Submit a work plan for chip seal removal. Include:
1.Description of equipment for chip seal removal
2.Procedure for residual chip seal removal from the deck after grinding or micro milling operations
3.Procedure for chip seal removal next to bridge rails, undulations, or drains
60-3.02A(4) Quality Assurance
Reserved
60-3.02B Materials
60-3.02B(1) General
Reserved
60-3.02B(2) Rapid Setting Concrete
Rapid setting concrete must comply with the specifications for bonding materials in section 51 -1.02C. You may extend rapid setting concr ete using a clean, uniform, and rounded aggregate filler with a moisture content of no more than 0.5 percent. Aggregate gradation must comply with the requirements shown in the following table: Sieve size Percentage passing 1/2" 100 No. 16 0–5 The amount of aggregate filler must comply with the manufacturer's instructions. Concrete strengths for extended concrete must be at least as specified for magnesium phosphate concrete. Combine components of dual -component magnesium phosphate by mixing only co mplete units supplied by the manufacturer. Do not add water to dual -component magnesium phosphate.
60-3.02C Construction
60-3.02C(1) General
Protect existing drain inlets, joint seals, joint seal assemblies, and other facilities to be incorporated into the new work from damage. Before starting deck rehabilitation activities, complete the removal of any traffic stripes, pavement markings, and pavement markers. Coarse aggregate remaining above the removal depth must be firmly embedded. SECTION 60 EXISTING STRUCTURES High-pressure water j et equipment must (1) have rotating or oscillating jets and (2) be rated at 30,000 psi minimum. Dust must not be blown into the air while blowing the deck. Cold milling equipment must:
1.Have a minimum concrete removal depth of 1/4 inch
2.Provide a surfa ce relief of at most 1/4 inch
3.Provide a 5/32 -inch grade tolerance Cold milling equipment must have:
1.3 or 4 riding tracks
2.Automatic grade control system with electronic averaging with 3 sensors on each side
3.Conveyer system that leaves no debris on the bridge
4.Drum that operates in an up -milling direction
5.Bullet tooth tools with tungsten carbide steel cutting tips
6.Maximum tool spacing of 1/4 inch
7.Maximum operating weight of 66,000 lb
8.Maximum track unit weight of 6,000 lb/ft
9.New tooth tools at the start of the work Micro milling equipment must:
1.Have a minimum concrete removal depth of 0.04 inch
2.Provide a surface relief of at most 0.045 inch
3.Provide a 5/32 -inch grade tolerance
4.Produce consistent depth of texture in the finished surface Micro milling equipment must have:
1.3 or 4 riding tracks
2.Automatic grade control system with electronic averaging and 3 sensors on each side
3.Conveyer system that leaves no debris on the bridge
4.Drum that operates in an up -milling direction
5.Bullet tooth tools with polycrystalline diamond enhanced cutting tips
6.Maximum tool spacing of 0.20 inch
7.Maximum operating weight of 66,000 lb
8.Maximum track unit weight of 6,000 lb/ft
9.New tooth tools at the start of the work Produce the finished surface using 2 passes of the micro milling equipment. Provide personnel on each side of the milling drum to monitor milling activities. Maintain constant radio communication with the operator during milling activities.
60-3.02C(2) Removing Concrete Deck Surface
Remove the concrete deck surface to the depth described. Before removing concrete , clean the deck surface by vacuuming, then blow the deck clean with high - pressure air . Remove the deck surface by micro milling or high -pressure water jetting.
60-3.02C(3) Removing Asphalt Concrete Surfacing
Where shown, remove asphalt concrete surfacing and re inforced concrete expansion dams from concrete bridges and approaches. Before removing asphalt concrete surfacing, verify the depth of the sur facing at the supports and midspans of each structure (1) in each shoulder, (2) in the traveled way, and (3) at the roadway crown, if a crown is present. SECTION 60 EXISTING STRUCTURES Remove asphalt concrete surfacing by cold milling under the following conditions:
1.If a membrane sea l is shown: 1.1. Remove the seal by cold milling 1.2. Do not remove more than 1/2 inch of the existing concrete slab
2.If a membrane seal is not shown: 2.1. Remove asphalt concrete surfacing until a 1/2 -inch minimum of surfacing remains on top of existing concrete slab 2.2. Use other authorized means to remove the remaining asphalt concrete without damage to the concrete slab Where a portion of the asphalt concrete surfacing is to remain, saw cut a 2 -inch-deep true line along the edge to remain in place b efore removing asphalt concrete. Remove the asphalt concrete without damaging the surfacing to remain in place.
60-3.02C(4) Removing Seals
Where shown, remove bituminous chip seals, bituminous slurry seals, and polymer chip seals entirely from bridge deck s by grinding or micro milling . Remove no more than 1/4 inch of concrete deck surface. Grinding must comply with section 42 -3. Any residual chip seals and other foreign materials remaining in the bridge deck after the grinding or micro milling operation must be removed by other authorized means.
60-3.02C(5) Removing Unsound Concrete
Where shown, remove unsound portions of bridge decks, curbs, and railings . Unsound concrete is concrete that emits a dead or hollow sound when chained or tapped with a metal tool. The Engineer determines the soundness of concrete. Equipment and tools that in the Engineer's opinion remove excess quantities of sound concrete are not allowed. For bridges over railroads, stop removal activities when trains pass under the bridge. Reinforcing steel exposed after removing unsound concrete must be restored to position an d blocked and tied under section 52. Replace or repair reinforcing steel damaged and rendered useless during removal.
60-3.02C(6) Rapid Setting Concrete Patch
Before placing rapid setting concrete patches, a brasive blast clean the contact surfaces of existing concrete and reinforcing steel. Remove at least 1/8 inch of concrete and all foreign mater ial. Immediately before placing new concrete, clean surfaces by vacuuming and (1) pressure jetting or (2) other authorized means to remove debris. The surface temperature of the existing concrete must be at least 40 degrees F during placement of the rapid setting concrete. Contact surfaces to receive magnesium phosphate concrete must be dry. Contact surfaces to receive modified high -alumina concrete or portland -cement -based concrete may be damp but not saturated. Magnesium phosphate concrete must not be mix ed in containers or worked with tools containing zinc, cadmium, aluminum, or copper. Modified high -alumina -based concrete must not be mixed in containers or worked with tools containing aluminum. Do not retemper concrete. Finishing tools cleaned with water must be thoroughly dried before working concrete. The Engineer may require that you use a flow -controlled modified concrete on slopes greater than 5 percent. Cure modified high-alumina -based concrete and portland -cement based concrete using the curing compound method. Do not cure magnesium phosphate concrete. SECTION 60 EXISTING STRUCTURES
60-3.02C(7) Prepare Concrete Deck Surface
Prepare concrete bridge decks (1) after the removal of any unsound concrete and placement of any rapid setting concrete patches and (2) before applying deck treatments or placing deck overlays. Perform the following activities in the order listed :
1.Abrasive blast the deck surface with steel shot. Steel shot must comply with SSPC -AB 3. Recycled steel shot must comply with SSPC -AB 2.
2.Clean the deck surface by vacuuming .
3.Blow the deck surface clean using high -pressure oil-free air. The deck surface must be dry when abrasive blasting is performed. Remove a ll laitance, surface contaminants, and foreign material from the deck surface. If the deck surface becomes contaminated or you allow traffic on the clean deck before placin g the deck treatment or overlay , abrasive blast clean the contaminated area , clean t he deck by vacuuming, and blow the deck surface clean using high -pressure oil -free air .
60-3.02C(8) Remove Polyester Concrete Overlay
Remove polyester concrete overlay by micro milling. Before removing the overlay, verify the depth of polyester concrete a t supports and midspan of each structure:
1.In each shoulder
2.In the traveled way
3.At the roadway crown, if a crown is present Remove no more than 1/8 inch of the underlying concrete surface. Remove residual polyester concrete remaining on the surfac e after micro milling by other authorized means. Do not damage the underlying concrete.
60-3.02C(9) 60-3.02C(15) Reserved
60-3.02D Payment
The payment quantity for rapid setting concrete (patch) is the volume determined from scale weights divided by a pl astic density of 135 lb/cu ft. If rapid setting concrete is used to fill voids from the removal of unsound concrete, the payment quantity for remove unsound concrete is the same as the payment quantity for rapid setting concrete (patch). No deduction is ma de for concrete used to fill spalls that existed before the work began.
60-3.03 Bridge Deck Treatment
60-3.03A General
60-3.03A(1) General
60-3.03A(2) Materials
Not Used
60-3.03A(3) Construction
Not Used
60-3.03A(4) Payment
Not Used SECTION 60 EXISTING STRUCTURES
60-3.03B Methacrylate Resin Bridge Deck Treatment
60-3.03B(1) General
60-3.03B(1)(a) Summary
Section 60 -3.03B includes specifications for treating bridge decks with a high -molecular -weight methacrylate resin .
60-3.03B(1)(b) Definitions
Reserved
60-3.03B(1)(c) Submittals
Submit a work plan for applying the methacrylate resin treatment . Include in the plan :
1.Schedule of work for the test area and for each bridge
2.Procedure for storing and handling resin components and absorbent material
3.Description of equipment for applying resin
4.Range of gel time and final cure time for resin
5.Description of absorbent material to be used
6.Description of equipment for applying and removing excess sand and absorbent material
7.Procedure for removing resin from the deck and equipment to be used
8.Procedure for avoiding spills or discharges of methacrylate, including materials and equipment
9.Procedure for cleaning up spills or discharges of methacrylate, including materials and equipment
10.Procedure for preventing resin from dripping from the structures
11.Procedure for disposing of excess resin and containers Submit an SDS for each resin component and diatomaceous earth shipment before use. Submit test samples of methacrylate resin components at least 15 days before use.
60-3.03B(1)(d) Quality Assurance
Complete a test area before starting deck treatment activities. Notify the Engineer at least 15 days before treating the test area. The test area must be:
1.At least 500 sq ft
2.Located within the project limits outside th e traveled way at an authorized location
3.Constructed (1) using the same materials, equipment, and construction methods to be used in the work and (2) under conditions similar to those anticipated when the work will be performed The completed test area must demonstrate (1) compliance with these specifications and (2) work will be completed within the time allowed. The Engineer performs friction testing of the treated test area under California Test 342. After completion of the test area , allow 10 days for the Engineer to perform the test ing. Do not perform deck treatment activities until the test area is authorized. The authorized test area is the standard of comparison in determining the acceptability of treated deck surfaces. The Engineer may perform testing under California Test 342 to verify the coefficient of friction of the treated deck surfaces. The coefficien t of friction of the treated surface must be at least 0.35 when tested under California Test 342.
60-3.03B(2) Materials
High-molecular -weight methacrylate resin consists of resin, promoter, and initiator. High-molecular -weight methacrylate resin must be l ow odor and comply with the requirements shown in the following table : SECTION 60 EXISTING STRUCTURES Quality characteristic Test method Requirement Volatile content (max, %) ASTM D 2369 , Method E 30 Viscositya (max, cP, Brookfield RV with UL adaptor, 50 RPM, at 25 °C ) ASTM D 2196 25 Specific gravitya (min, at 25 °C ) ASTM D 1475 0.90 Flash pointa (min, °C) ASTM D 3278 82 Vapor pressurea (max, mm Hg , at 25 °C ) ASTM D 323 1.0 Tack -free time (max, minutes) except Sample 50 ± 5 g Test 2 ± 0.05 g in 55 ± 5 mm diameter disposable aluminum weighing dish ASTM C679 400 PCC -saturated surface -dry bond strength (min, psi, at 24 hours and 70 ± 2 °F) California Test 551 500 aPerform test before adding the initiator. Sand for the abrasive sand finish must be a commercial -quality, dry -blast sand. The size of the sand must be such that not less than 95 percent passes the no. 8 sieve and not less than 95 percent is retained on the no. 20 sieve when tested under California Test 205. Absorbent material must be diatomaceous earth, abrasive blast dust, or an authorized substitute recommended by the resin supplier.
60-3.03B(3) Construction
Notify the Engineer at least 15 days before delivery of methacrylate resin components in containers larger than 55 gallons to the job site. The Engineer determines the exact methacrylate resin application rate at time of placement. High-molecular -weight methacrylate r esin applied by machine must be (1) combined in volumetric streams of promoted resin to initiated resin by static in-line mixers and (2) applied without atomization. You may apply resin manually. Mix at most 5 gallons of resin at a time. The deck must be dry before applying resin. The concrete surface must be from 50 to 100 degrees F. Relative humidity must be not mor e than 85 percent during the work shift. Thoroughly mix all resin components. Apply resin to the deck within 5 minutes of mixing at an approximate application rate of 90 sq ft/gal. Resin that thickens during application is rejected. Uniformly spread the re sin. Completely cover surfaces to be treated and fill all cracks. Redistribute excess resin using squeegees or brooms within 10 minutes of application. For textured or grooved deck surfaces, remove excess resin from the texture indentations. Apply the abrasive sand finish no sooner than 20 minutes after applying the resin. The sand application rate must be at least 2 lb/sq yd or until saturation as determined by the Engineer. Apply absorbent material before opening the lane to traffic. Remove excess sand and absorbent material by vacuuming or power sweeping. Traffic or equipment is not allowed on the treated surface until you have verified that the following requirements have been met and the opening of the treated surface to traffic and equipm ent is authorized :
1.Treated deck surface is tack free and not oily
2.Sand cover adheres and resists brushing by hand
3.Excess sand and absorbent material has been removed
4.No material will be tracked beyond the limits of treatment by traffic Remove resin from the deck surface if the Engineer determines (1) the conditions listed above have not been met and (2) the allowable lane closure time will be exceeded. SECTION 60 EXISTING STRUCTURES
60-3.03B(4) Payment
The payment quantity for furnish bridge deck treatment material is the v olume of mixed high -molecular - weight methacrylate resin placed.
60-3.03C 60-3.03J Reserved
60-3.04 Deck Overlays
60-3.04A General
60-3.04A(1) General
Section 60 -3.04 includes specifications for overlaying concrete bridge decks.
60-3.04A(2) Materials
Not Used
60-3.04A(3) Construction
Not Used
60-3.04A(4) Payment
Not Used
60-3.04B Polyester Concrete Overlays
60-3.04B(1) General
60-3.04B(1)(a) Summary
Section 60 -3.04B includes specifications for placing polyester concrete overlays on concr ete bridge decks . Placing polyester concrete overlay includes placing a prime coat of methacrylate resin to the bridge deck before placing the polyester concr ete overlay. Furnishing polyester concrete includes furnishing and placing the trial overlay and concrete base for the trial overlay.
60-3.04B(1)(b) Definitions
Reserved
60-3.04B(1)(c) Submittals
Submit a work plan for the placement of the deck overlay. Include the following in the work plan :
1.Schedule of overlay work for each bridge and a schedule of work for any trial overlays
2.Method for storage and handling of methacrylate resin and polyester concrete components
3.Description of equipment for app lying methacrylate resin
4.Description of equipment for measuring, mixing, placing, and finishing the polyester concrete overlay
5.Method for isolating expansion joints and drainage
6.Cure time for polyester concrete
7.Description of equipment for appl ying sand
8.Method for avoiding spills or discharges of methacrylate and polyester concrete, including materials and equipment
9.Method for cleaning up spills or discharge of methacrylate and polyester concrete, including materials and equipment
10.Procedure for preventing resin from dripping from the structures
11.Method for disposal of excess methacrylate resin, polyester concrete, and containers For each shipment of methacrylate and polyester concrete, submit an SDS for each component. Submit test samples of methacrylate resins, polyester resins , and aggregates with a certificate of compliance and manufacturer's test results at least 15 days befor e use. Submit aggregate and resin volumes recorded from the volumetric mixer at the end of each work shift. SECTION 60 EXISTING STRUCTURES
60-3.04B(1)(d) Quality Assurance
Complete a trial polyester concrete overlay before starting overlay activities. Notify the Engineer at least 15 days before constructing the trial overlay. The trial overlay must be:
1.At least 12 by 12 feet and the same thickness as the overlay shown
2.Constructed on a prepared concrete base within the project limits at an authorized location
3.Constructed (1) u sing the same materials, equipment, and construction methods to be used in the work and (2) under conditions similar to those anticipated when the work will be performed Use the trial overlay to determine the initial polyester -concrete set time. The Engin eer performs friction testing of the trial overlay under California Test 342. After completion of the trial overlay , allow 10 days for the Engineer to perform the testing. The completed trial overlay must demonstrate (1) compliance with these specification s and (2) that the work will be completed within the time allowed. Do not perform overlay activities until the trial overlay is authorized. The authorized trial overlay is the standard of comparison in determining the acceptability of the overlay. The Engi neer may perform testing under California Test 342 to verify the coefficient of friction of the overlay surfaces. Dispose of the trial overlay and concrete base after acceptance of all polyester concrete overlay surfaces. Place polyester concrete overlay on:
1.Portland cement concrete no sooner than 28 days after concrete placement
2.Portland cement based RSC no sooner than 14 days after concrete placement and your test results for prequalification of RSC show that the concrete attained at least 3,500 psi compressive strength
3.RSC using hydraulic cement other than portland cement or portland limestone cement no sooner than 3 days after concrete placement and your test results for prequalification of RSC show that the concrete attained at least 3,500 psi compressive strength
4.Magnesium phosphate based rapid setting concrete patch material no sooner than 3 days after final set
5.Modified high -alumina -based rapid setting concrete patch material no sooner than 30 minutes after final set
60-3.04B(2) Mater ials
Polyester concrete consists of polyester resin binder and aggregate. Polyester resin binder must:
1.Be an unsaturated isophthalic polyester -styrene copolymer
2.Contain not less than 1 percent by weight gamma -methacryloxypropyltrimethoxysilane, an organosilane ester silane coupler
3.Be used with a promoter compatible with suitable methyl ethyl ketone peroxide and cumene hydroperoxide initiators
4.Comply with the requirements shown in the following table : SECTION 60 EXISTING STRUCTURES Quality characteristic Test method Requirement Viscositya (cP, RV, no. 1 spindle, 20 RPM, at 25 °C) ASTM D2196 75–200 Specific gravitya (at 25 °C) ASTM D1475 1.05–1.10 Elongation (min, %) Type I specimen, 0.25 ± 0.03 inch thick Rate = 0.45 in/min Sample Conditioning: 18/25/50+5/70 ASTM D638 ASTM D618 35 Tensile strength (min, psi) Type I specimen, 0.25 ± 0.03 inch thick Rate = 0.45 in/min Sample conditioning: 18/25/50+5/70 ASTM D638 ASTM D618 2,500 Styrene contenta (%, by weight) ASTM D2369 40–50 PCC saturated surface -dry bond strength (min, psi, at 24 hours and 70 ± 2 °F) California Test 551 500 Static volatile emissiona (max, g/sq m loss) SCAQMD Method 309 - 91 60 aTest must be performed before adding initiator. Aggregate for polyester concrete must:
1.Comply with sections 90 -1.02C(1), 90 -1.02C(2), and 90 -1.02C(3), except fine aggregate must consist of natural sand
2.Have not more than 45 percent crushed particles retained on the no. 8 sieve when tested under California Test 205
3.Have a weighted -average aggregate absorption of not more than 1 percent when tested under California Tests 206 and 207
4.At the time of mixing with resin, have a moisture content of not more than one half of the weighted - average agg regate absorption when tested under California Test 226
5.Comply with the percentage passing limits for one of the aggregate gradations shown in the following table: Aggregate Gradation Sieve size Percentage passing 3/8 inch maximum No. 4 maximum 1/2" 100 100 3/8" 83–100 100 No. 4 65–82 62–85 No. 8 45–64 45–67 No. 16 27–48 29–50 No. 30 12–30 16–36 No. 50 6–17 5–20 No. 100 0–7 0–7 No. 200 0–3 0–3 High-molecular -weight methacrylate for the resin prime coat must comply with section 60 -3.03B except:
1.Methacrylate resin must be free of wax
2.Tack -free time requirements do not apply
3.Friction testing is not required for the resin prime coat Sand for abrasive sand finish must:
1.Be commercial -quality blast sand
2.Be grade d such that not less than 95 percent passes the no. 8 sieve and not less than 95 percent is retained on the no. 20 sieve when tested under California Test 205
3.Have an average absorption of not more than 1 percent when tested under California Test 207 SECTION 60 EXISTING STRUCTURES
60-3.04B(3) Construction
60-3.04B(3)(a) General
Notify the Engineer at least 15 days before delivery of methacrylate resin components in containers larger than 55 gallons to the job site. The Engineer provides the final grade and cross slope before the st art of overlay work. Complete the construction of approach slabs before placing polyester overlay. New concrete deck surfaces must comply with section 51 -1.03F(5) before starting overlay work.
60-3.04B(3)(b) Placing Methacrylate Resin
The Engineer determi nes the exact percentage of polyester resin binder at the time of placing. The deck must be dry before placing the methacrylate prime coat. The concrete surface must be from 50 to 100 degrees F and the relative humidity must be not more than 85 percent. Clean the deck by vacuuming, then blow the deck clean with high -pressure oil -free air. Dust must not be blown into the air while blowing the deck. Thoroughly mix all components of the methacrylate resin. Apply the resin to the deck surface within 5 minutes o f mixing. Apply the resin u niformly and spread to completely cover surfaces to be overlaid. Apply methacrylate resin at an approximate rate of (1) 55 sq ft/gal where deck surface is removed or (2) 90 sq ft/gal where deck surface is not removed .
60-3.04B(3) (c) Placing Polyester Concrete
Use a continuous mixer to mix polyester concrete. The continuous mixer must:
1.Employ an auger screw device with a discharge chute
2.Be equipped with an automatic metering device that measures and records aggregate and res in volumes
3.Have a visible readout gage that displays volumes of aggregate and resin being recorded
4.Be certified under California Test 109 before use
5.Produce a satisfactory mix consistently during a demonstration Record polyester concrete volumes at least every 5 minutes, including time and date. Finishing equipment for polyester concrete must:
1.Have grade control capabilities resulting in a roadway surface that meets the smoothness requirements of section 51-1.01D(3)(b)(ii) and is capabl e of adjusting for a variable thickness overlay along and across the existing deck surface. The use of fixed height skid -supported strike off equipment is not allowed.
2.Be used to consolidate the polyester concrete .
3.Have a 12 -foot minimum paving width .
4.Be self -propelled and equipped with automatic screed controls and sensing devices that control the thickness, longitudinal grade, and transverse screed slope. Advancing the finishing equipment with winches or a pulling device is not allowed. Place po lyester concrete:
1.Immediately after applying the methacrylate prime coat
2.Before gelling occurs
3.Within 15 minutes of adding the initiator The weight of resin binder must be approximately 12 percent of the weight of the aggregate. Polyester concret e must have an initial set time from 30 to 120 minutes when tested using an initial -setting -time Gillmore needle under ASTM C266. SECTION 60 EXISTING STRUCTURES Consolidate and finish the overlay to the required grade and cross section using finishing equipment. Polyester concrete must be consolidated to a relative compaction of not less than 97 percent when tested under California Test 552. Texture the polyester concrete surface before gelling occurs by longitudinal tining under 51 - 1.03F(5)(b)(iii), except do not perform initial texturi ng. Apply a sand finish of not less than 0.8 lb/sq yd before gelling occurs. Protect the overlay from moisture and do not allow traffic or equipment on the overlay (1) for a minimum of 4-hour cure time after final finishing and (2) until each rebound test result for the final finish shows a reading of at least 28 when tested under ASTM C805. The cure time must be extended if ordered. The rebound test may not be used to reduce the 4 -hour cure time of the overlay. Completed polyester concrete dec k surfaces must have a uniform surface texture with a coefficient of friction of at least 0.35 when tested under California Test 342 and a surface smoothness complying with section 51 -1.01D(3)(b)(ii). Taper the polyester concrete overlay edges if the overl ay (1) is not completed within the allowable lane closure time and (2) is more than 1/2 inch higher in elevation than the adjacent pavement. Taper the edges that are longitudinal to the direction of traffic at a 4:1 (horizontal:vertical) slope. Tapers may remain and be overlaid with polyester concrete overlay.
60-3.04B(4) Payment
The payment quantity for furnish polyester concrete overlay is the volume determined using:
1.Quantity of resin binder used
2.Percentage by weight of resin binder in the polyest er concrete
3.Unit weight of 135 lb/cu ft
60-3.04C Polyester Concrete Expansion Dams
60-3.04C(1) General
60-3.04C(1)(a) Summary
Section 60 -3.04C includes specifications for constructing polyester concrete expansion dams. Polyester concrete expansion dams must comply with the specifications for polyester concrete overlays in section 60 -3.04B, except a trial overlay is not required. Reinforcement must comply with section 52.
60-3.04C(1)(b) Definitions
Reserved
60-3.04C(1)(c) Submittals
Reserved
60-3.04C(1)(d) Quality Assurance
Reserved
60-3.04C(2) Materials
Not Used
60-3.04C(3) Construction
For new asphalt concrete overlays, place the asphalt concrete overlay before starting pol yester concrete activities. Saw cut and remove asphalt concrete at expansion dam locations. For existing asphalt concrete overlays, remove expansion dams and asphalt concrete to the limits shown. Removing expansion dams must comply with section 60 -2.02, ex cept a bridge removal work plan is not required. SECTION 60 EXISTING STRUCTURES Where a portion of the asphalt concrete overlay is to remain, saw cut a 2 -inch-deep true line along the edge to remain in place before removing the asphalt concrete. Do not damage the existing surfacing to remain in place. Prepare the deck surface under section 60 -3.02C(7). You may use a mechanical mixer to mix the polyester concrete for expansion dams. The mixer capacity must not exceed 9 cu ft unless authorized. Initiate the resin and thoroughly blend it im mediately before mixing it with the aggregate. Mix the polyester concrete for at least 2 minutes before placing. The application rate of methacrylate resin must be approximately 100 sq ft/gal. You may place and finish expansion dams using hand methods. Protect expansion dams from moisture, traffic, and equipment for at least 4 hours after finishing. For expansion dams over 6 feet long, install 1/4 -inch-wide joint material at 6 -foot intervals across the width of the expansion dam. Joint material must be eith er expanded polyurethane or expanded polyethylene.
60-3.04C(4) Payment
The payment quantity for polyester concrete expansion dam is the volume determined from the dimensions shown.
60-3.04D Concrete Overlays
60-3.04D(1) General
Section 60 -3.04D includes specifications for overlaying bridge decks with concrete. Constructing concrete overlays must comply with section 51.
60-3.04D(2) Materials
Not Used
60-3.04D(3) Construction
Not Used
60-3.04D(4) Payment
Not Used
60-3.04E Multilayer Polymer Ove rlays
Reserved
60-3.04F 60-3.04M Reserved
60-3.05 Repairing Structures
60-3.05A General
60-3.05A(1) General
60-3.05A(2) Materials
Not Used
60-3.05A(3) Construction
Not Used
60-3.05A(4) Payment
Not Used SECTION 60 EXISTING STRUCTURES
60-3.05B Repairing Spalled Surface Areas
60-3.05B(1) General
60-3.05B(1)(a) Summary
Section 60 -3.05B includes specifications for repairing spalled concrete surfaces except on bridge decks.
60-3.05B(1)(b) Definitions
Reserved
60-3.05B(1)(c) Submittals
For alternative filler material, submit a test sample of at least 1 complete unit of all materials for repairing the concrete surfaces. Allow 45 days for testing. For a contract with less than 60 original working days, submit certificates of compliance for the filler material and bonding agents.
60-3.05B(1)(d) Quality Assurance
Reserved
60-3.05B(2) Materials
Mortar must comply with sect ion 51 -1.02F. Shotcrete must comply with section 53. Alternative filler materials and bonding agents must comply with the requirements shown in the following table: Quality characteristic Test method Requirement Abrasion resistance (max, grams, at 28 days) California Test 550 25 Modulus of elasticity (psi, at 28 days) California Test 551 1.5 x 106–3.5 x 106 Water soluble chlorides (max, mg/kg) California Test 422 500 Water soluble sulfates (max, mg/kg) California Test 417 2,500 For a contract with less than 60 original working days, alternative materials must be authorized before use.
60-3.05B(3) Construction
Remove unsound concrete under section 60 -3.02C(5). Clean concrete surfaces and existing reinforcing steel by abrasive blasting before placing filler material. Place reinforcing steel where shown. Fill spalled surface areas under section 51 -1.03F(2) or you may use an authorized alternative filler material and bonding agent. If using an alternative filler material, apply a bonding e poxy before placing the filler material. Place the filler material under the manufacturer's instructions. If using shotcrete, you may apply the shotcrete using a dry -mix process with a hydration liquid applied immediately after placing the shotcrete. The f inal surface finish of the patched concrete surface must comply with section 51 -1.03F. Patched concrete must emit a ringing sound similar to adjacent sound concrete when struck with a metal tool 14 days after placement. Removing and patching spalled concre te more than 4 inches deep is change order work.
60-3.05B(4) Payment
The payment quantity for repair spalled surface area is the area measured of the completed repaired surface. Measured areas are recorded daily by the Engineer and agreed upon by you. SECTION 60 EXISTING STRUCTURES
60-3.05C Epoxy Crack Injection
60-3.05C(1) General
60-3.05C(1)(a) Summary
Section 60 -3.05C includes specifications for filling cracks in concrete structures with pressure -injected epoxy.
60-3.05C(1)(b) Definitions
Reserved
60-3.05C(1)(c) Submittals
Reserved
60-3.05C(1)(d) Quality Assurance
Before starting injection activities and at hourly intervals when requested, take a 3 -ounce sample of mixed epoxy from the injection gun. If samples show improper proportioning or mixing, stop injection activities and correct deficiencies.
60-3.05C(2) Materials
Epoxy must comply with the specifications for epoxy r esin adhesive for injection grouting of concrete pavement. Multiple formulations may be required for cracks of varying widths.
60-3.05C(3) Construction
The Engineer selects cracks having widths from 8 to 250 mils for injection and filling. Clean cracks of material that would impair bonding of epoxy using oil -free compressed air. Remove any remaining material by flushing with water under pressure. After flushing, blow cracks clean with oil -free compressed air. Insert injection ports into cracks. Space the p orts not more than a distance equal to the thickness of the concrete being injected. Spacing at ends of cracks must be equal to half the concrete thickness. Adjust port spacing to ensure epoxy substantially fills the cracks. Seal the crack surfaces between ports with tape or other temporary sealant capable of retaining epoxy in cracks during pressure injection and until epoxy has hardened. Concrete temperature must be from 50 to 90 degrees F during injection activities . Pressure inject epoxy adhesive into c racks through injection ports. Use the lowest practical pumping pressure. Injection equipment must maintain epoxy proportion and mix consistency. Fill cracks completely. Do not allow epoxy to run down the face of the concrete from the head of the injection gun. Start injection at the 1st port at the end of a crack. Pump epoxy into the port until epoxy runs substantially from the adjacent port. Seal the 1st port and start injection from the next port. Continue in this manner until the crack is filled. For sl anting or vertical cracks, start injecting at the lower end of the crack. Where vertical and horizontal cracks intersect, inject the vertical crack below the intersection first. Seal ports by removing the fitting, filling the void with epoxy, and covering the void with tape or surface sealant. Leave the sealing tape and temporary surface sealant in place until the epoxy has hardened. Clean excess epoxy from concrete surfaces exposed to public view after removing sealant.
60-3.05C(4) Payment
For cracks exte nding around corners of members, the payment quantity for inject crack epoxy is the crack length measured on both faces, including the crack length shown to be filled on the opposite side of a member that is completely filled after injection from only 1 si de.
60-3.05D Heat -Straighten Steel Girders
Reserved
60-3.05E Galvanic Anodes
Reserved SECTION 60 EXISTING STRUCTURES
60-3.05F Replace Bearings
60-3.05F(1) General
Section 60 -3.05F includes specifications for replacing bearing pads or steel rocker bearings with elastomeric bearing pads. Elastomeric bearing pads must comply with section 51 -3.02. Temporary supports must comply with section 48 -3. Jacking must comply with section 48 -5.
60-3.05F(2) Materials
Not Used
60-3.05F(3) Construction
Temporary supports must include jack ing assemblies to jack and support the imposed loads and structures. Temporary or permanent stiffening members are required at all girder locations, directly above the applied jacking forces, unless otherwise authorized. When the bridge is in the raised po sition, do not allow traffic on the bridge until the structure is secured and fully supported by temporary supports. Remove the existing bearing pads and steel rocker bearings under section 60 -2.02, except a bridge removal work plan is not required. For st eel rocker bearings, remove the existing steel keeper plates, steel masonry plates, grout pads, anchor bolts and rocker bearings. Flame or air -arc type of cutting equipment is not allowed to remove existing keeper plates. Sharp, marred, or roughened corner s and edges resulting from removal operations must be slightly rounded by grinding or other suitable means. Steam clean existing bearing seats and bearing contact areas on the bottoms of concrete girders to remove waxy residue and other deleterious materia ls. Use oil -free compressed air for final cleaning to remove all loose material from bearing contact areas before placing new elastomeric bearing pads. Verify bearing surface of seats are level. Ensure equal bearing on the entire area of each pad.
60-3.05F(4) Payment
Not Used
60-3.05G 60-3.05J Reserved
60-3.06 60-3.10 Reserved
60-4 Modifying Structures
60-4.01 General
60-4.01A General
60-4.01B Materials
Not Used
60-4.01C Construction
Not Used
60-4.01D Payment
Not Used
60-4.02 Refinishing Bridge Decks
60-4.02A General
SECTION 60 EXISTING STRUCTURES The Eng ineer determines the exact area to be refinished.
60-4.02B Materials
Concrete for refinishing bridge decks must be either portland cement concrete or rapid setting concrete. Portland cement concrete must comply with section 90 -1 and the following:
1.Conc rete must contain at least 675 pounds of cementitious material per cubic yard.
2.Free water must not exceed 280 lb/cu yd.
3.Aggregate must contain from 50 to 55 percent fine aggregate. The remaining portion must be pea gravel. Grade pea gravel such that 100 percent passes the 1/2 -inch sieve and at most 5 percent passes the no. 16 sieve.
4.Engineer may request that admixtures be used. Rapid setting concrete must comply with section 60 -3.02. Epoxy adhesive must comply with the specifications for epoxy adh esive for bonding freshly mixed concrete to hardened concrete.
60-4.02C Construction
60-4.02C(1) General
For removal work performed within 10 feet of a traffic lane or over a traffic lane, remove the dust and residue using an authorized vacuum, a water s pray, or a shield method. Make a 3/4 -inch-deep saw cut around the perimeter of the deck to be refinished. Remove concrete in areas to be refinished to a depth of approximately 3/4 inch. Do not damage concrete to remain in place. Prepare existing deck areas more than 3/4 inch below adjoining deck surfaces by removing at least 1/4 inch of surface material to expose sound aggregate. Remove concrete by abrasive blast cutting, abrasive sawing, impact tool cutting, machine rotary abrading, or other methods. Remov al methods must be authorized. Clean prepared areas of dust and loose and deleterious materials by vacuuming , abrasive blast cleaning, and using high -pressure oil-free air. Re -blast contaminated areas before starting concrete placement activities. Dust must not be blown into the air while blowing the deck. Protect existing reinforcement exposed during concrete removal. Cut off dowels 1 inch below the existing deck surface or at the bottom of concrete removal, whichever is lower. Where refinishing is not required, cut dowels off 1 inch below the finished surface. Patch holes with rapid setting concrete complying with section 60 -3.02. You may refinish isolated high areas by cutting the concrete down flush with adjoining deck surface s. Use abrasive sawing, grinding, impact tool cutting, or other authorized methods. Fill prepared areas flush with the plane of the adjoining deck using concrete. Transversely score fresh concrete surfaces. Use a stiff -bristled broom or other suitable devi ce. Completed surfaces must have a uniform texture with a coefficient of friction of at least 0.35 when tested under California Test 342. Grind or groove surfaces having a coefficient of friction less than 0.35 under section 42. Refinished surfaces must (1 ) be flush with the adjoining surface and (2) not vary more than 0.02 foot from the lower edge of a 12 -foot straightedge placed in the longitudinal direction.
60-4.02C(2) Placing Portland Cement Concrete
Abrasive -blast clean concrete surfaces to be refini shed. Clean blast -cleaned surfaces by vacuuming, then blow them clean using high -pressure oil-free air. Dust must not be blown into the air while blowing the deck. SECTION 60 EXISTING STRUCTURES Apply an epoxy adhesive to cleaned surfaces immediately after cleaning. Surfaces must be dry and have a temperature of at least 40 degrees F when applying the adhesive. The Engineer determines the application rate. Place concrete on fresh epoxy adhesive. Consolidate concrete immediately after placement until voids are filled and free mortar appea rs on the surface. Strike off concrete to the required grade. Cure concrete under section 51 -1.03H. Do not apply loads of any type to the concrete until at least 7 days after placement.
60-4.02C(3) Placing Rapid Setting Concrete
Blow surfaces to be refini shed with high -pressure oil -free air immediately before placing rapid setting concrete. Abrasive -blast clean concrete surfaces that are contaminated before the concrete is placed. Allow traffic on new concrete under the manufacturer's instructions and when authorized .
60-4.02D Payment
The payment quantity for refinish bridge deck is the sum of (1) the area measured along the surface and
2.0.2 square foot for patching around each dowel. The Department does not adjust the unit price for an increase or decr ease in the refinish bridge deck quantity.
60-4.03 Access Openings
60-4.03A General
Section 60 -4.03 includes specifications for constructing access openings and closing access openings when access is no longer required. Reinforcement must comply with section 52. Steel plates, hardware, and thread -locking compound must comply with section 75 -3.
60-4.03B Materials
Rapid -setting concrete must comply with section 60 -3.02B(2).
60-4.03C Construction
60-4.03C(1) General
Removing portions of bridges must comply with section 60 -2. Limits of removal shown are approximate. The Engineer must authorize removal limits before you start removal activities. Paint exposed ends of the remaining reinforcement with 2 coats of organic zinc -rich coating as specified for exposed ends of prestressing steel in section 50 -1.03B(3)(a). Within cells where work activities are performed, remove existing formwork and concrete that interfere with the work. In cells that adjoin hinges, bent caps, or abutments, remove existing forms and sharp projections in the cell between the adjoined element and 5 feet past the access opening.
60-4.03C(2) Deck Access Openings
Remove portions of existing bridge decks , including bar reinforcing steel, at the locations shown.
60-4.03C(3) Soffit Access Openings
Remove portions of the existing soffit, including the bar reinforcing steel, at the locations shown. Seal the access openings with access doors when cell access is no longer required.
60-4.03C(4) Soffit Access Opening Extensions
For bridge soffit access opening extensions, remove and replace concrete to the limits shown. You may reduce removal limits if authorized. Reconstruct and seal soffit access openings to t he original dimensions when cell access is no longer required. SECTION 60 EXISTING STRUCTURES Use concrete or rapid -setting concrete to reconstruct the access openings. Placing concrete must comply with section 51. Placing rapid -setting concrete must comply with section 60 -3.02C(6).
60-4.03C(5) Close Deck Access Openings
Close deck access openings using rapid -setting concrete. Placing rapid -setting concrete must comply with section 60 -3.02C(6). Use water to flush dust from areas to be filled with concrete. Remove all water by air blasti ng before placing concrete. Allow traffic on new concrete under the manufacturer's instructions and when authorized. If the close deck access opening work has not been completed, use temporary deck cover plates to temporarily close the deck access openings before opening the lane to traffic. Temporary deck cover plates must remain in place until the deck access opening is permanently closed.
60-4.03D Payment
Not Used
60-4.04 Coring Concrete
60-4.04A General
60-4.04A(1) Summary
Section 60 -4.04 includes s pecifications for coring holes through concrete structures.
60-4.04A(2) Definitions
Reserved
60-4.04A(3) Submittals
If cored holes are greater than 10 feet in length, submit:
1.Work plan for the coring activities, including methods and equipment to be used
2.Labeled cores If reinforcement shown not to be cut is cut during coring operations, submit a work plan for (1) repairing the cut reinforcement and (2) preventing cutting of addi tional reinforcement. Allow 3 business days for review.
60-4.04A(4) Quality Assurance
Reserved
60-4.04B Materials
Water for coring activities must either (1) be from the local water supply or (2) contain:
1.Not more than 1,000 ppm chlorides as Cl
2.Not more than 1,300 ppm of sulfates as SO 4
3.No impurities that discolor the concrete or etch the surface
60-4.04C Construction
Use coring methods that do not shatter or damage the concrete adjacent to the holes. Stop coring operations if reinforcement sho wn not to be cut is cut during coring operations. Do not resume coring operations until your work plan is authorized. If cored holes are greater than 10 feet in length:
1.Alignment of the cored hole must not deviate from that shown by more than 1/2 inch p er 10 feet of length with a total maximum deviation of 3 inches
2.Label each core with the core location immediately after coring SECTION 60 EXISTING STRUCTURES Do not allow water from coring activities to fall onto traffic, flow across shoulders or lanes occupied by traffic, or flow into gutters or other drainage facilities.
60-4.04D Payment
The payment quantity for core concrete is the length measured along the centerline of the hole. The payment quantity includes the length of any expansion joints.
60-4.05 Coring and Pressure Grou Ting Dowels
60-4.05A General
Section 60 -4.05 includes specifications for coring holes through concrete and grouting dowels into the cored holes. Coring must comply with section 60 -4.04.
60-4.05B Materials
Grout must comply with ASTM C1107 or ASTM C845, Type K, with a compressive strength of 5,000 psi at 28 days when tested under California Test 551. Dowels must comply with the specifications for bar reinforcing steel in section 52. Water for grout must comply wit h the specifications for water in section 90 -1.02D. Admixtures must not contain more than 500 ppm of chlorides as Cl when tested under California Test 422 and not more than 2,500 ppm of sulfates as SO 4 when tested under California Test 417.
60-4.05C Const ruction
Clean loose and foreign material from concrete and steel surfaces that will be in contact with the grout. Flush holes with water and let them dry to a surface -dry condition immediately before grouting. Seal the ends of holes after placing the dowel s. Place a vent tube at one end of the hole and an injection feed tube at the other end of the hole. For holes with only a single end, place vent and injection feed tubes in the same end. Place tubes such that the air will vent and the hole will be complet ely filled with grout. Mix grout under the manufacturer's instructions. Pump grout into holes. Use sufficient pressure so that the hole is free of voids. Continually waste grout until air and water eject from the vent tubes and there are no visible slugs.
60-4.05D Payment
Payment for furnishing dowels is not included in the payment for core and pressure grout dowel.
60-4.06 Steel Column Casings
60-4.06A General
60-4.06A(1) Summary
Section 60 -4.06 includes specifications for fabricating, installing, and cleaning and painting steel column casings. Column casings must comply with the specifications for structural steel in section 55. Cleaning and painting column casings must comply with the specifications for cleaning and painting new structural steel in section 59 -2.
60-4.06A(2) Definitions
Reserved
60-4.06A(3) Submittals
Reserved
60-4.06A(4) Quality Assurance
For field welding of column casings: SECTION 60 EXISTING STRUCTURES
1.Only visual inspection is required
2.2nd sentence of clause 5.13.2 and the 1st sentence of clause 5.13.3 of AWS D1.5 do not apply
60-4.06B Materials
60-4.06B(1) General
Steel for casings must comply with ASTM A36/A36M or ASTM A709/A709M, Grade 36. Mortar must comply with section 51 -1.02F. Polyethylene must have a compressive stren gth of at least 10 psi at no more than 15 percent deflection when tested under ASTM D3575, Suffix D. Drain extension pipe must comply with the specifications for drainage piping in section 75 -3.
60-4.06B(2) Grout
Grout must consist of cement and water, an d may contain an admixture if authorized. Do not exceed 5 gallons of water per 94 lb of cement. Cement must comply with section 90 -1.02B(2). Water must comply with section 90 -1.02D. Admixtures must comply with section 90, except admixtures must not contain chloride ions in excess of 0.25 percent by weight. For noncircular columns with a maximum gap greater than 4 inches, extend the grout as follows:
1.Aggregate must consist of at least 70 percent fine aggregate and approximately 30 percent pea gravel, by w eight.
2.Fine aggregate must comply with section 90 -1.02C(3).
3.Size of pea gravel must be such that 100 percent passes the 1/2 -inch sieve, at least 90 percent passes the 3/8 -inch sieve, and not more than 5 percent passes the no. 8 sieve.
4.Minimum ceme nt content of the grout must not be less than 845 lb/cu yd. Mix the grout as follows:
1.Add water to the mixer followed by cement and any aggregates or admixtures.
2.Mix the grout with mechanical mixing equipment that produces a uniform and thoroughly m ixed grout.
3.Agitate the grout continuously until the grout is pumped.
4.Do not add water after initial mixing.
60-4.06C Construction
60-4.06C(1) General
Remove and dispose of all material from the space to be occupied by column casing materials. Bond polyethylene to column surfaces where shown. Use an authorized waterproof adhesive. Apply adhesive to the entire contact surface. Use spacers to center casings around columns during placement. You may weld spacers to the inside of casings. Do not use spacers in areas where polyethylene is used. Paint the information that is on existing columns onto casings under section 51 -1.03E(1).
60-4.06C(2) Painting
Apply the undercoat before shipment to the job site. Do not paint surfaces that are to b e thermal spray coated or covered with polyethylene. Apply final coats after installing the casing.
60-4.06C(3) Grouting
Grout the space between casing and column faces. SECTION 60 EXISTING STRUCTURES Grouting equipment must comply with section 50 -1.03B(2)(d)(ii). If hot weather condit ions will contribute to quick stiffening of the grout, cool the grout by authorized methods as necessary to prevent blockages during pumping activities. If freezing weather conditions are anticipated during and following the placement of grout, provide adequate means to protect the grout in the casings from damage by freezing. Do not:
1.Allow the grout temperature to rise above 90 degrees F during mixing and pumping
2.Grout when the ambient or grout temperature is less than 50 degrees F Limit the height of each grout lift to minimize casing undulations and displacements. Undulations in the casing surface must not exceed 1/4 inch in 12 inches. Total casing displacement from the position shown must not exceed 2 inches at any point. You may use bracing or ot her means to restrain casing. Except where shown, restraints may not pass through columns. Allow grout to harden before placing the next lift of grout unless a bracing system is used. The maximum height of grout lifts for portions of casings with polyethyl ene is 10 feet. Install external injection valves for grouting casings. Begin filling casing from the bottom. Space valves so that grout fills the void between the casing and the column. Seal casings at the bottom. Pump grout such that a uniform grout head around the column is maintained and no visible water or air is ejected from the top of the grout. Cover grout at the casing top with mortar. Slope mortar to drain. Remove accessories from casings no sooner than 24 hours after placing grout. Voids must be filled with mortar and finished flush with the exterior casing surface.
60-4.06D Payment
Not Used
60-4.07 Composite Columns Casings
Reserved
60-4.08 Prestressing Steel Girders
Reserved
60-4.09 Bridge Joint Restrainers
60-4.09A General
60-4.09A(1) Summary
Section 60 -4.09 includes specifications for fabricating and installing bridge joint restrainers. Bridge joint restrainers must comply with the specifications for miscellaneous bridge metal in section 75 -3.
60-4.09A(2) Definitions
Reserved
60-4.09A(3) Submittals
60-4.09A(3)(a) General
Reserved
60-4.09A(3)(b) Cable -Type Restrainers
Submit 2 certified copies of mill test reports for each manufactured length of cable. Submit 2 certified copies of the mil l test and heat treating reports for each heat of bars used for cable yield indicators. SECTION 60 EXISTING STRUCTURES Submit at the manufacturer's plant:
1.1 cable -type restrainer test sample for each 200 restrainers or fraction thereof produced. The sample restrainer must: 1.1. Consist of a cable fitted with a swaged fitting and right -hand thread stud at both ends 1.2. Be 3 feet in total length
2.1 turnbuckle fitted with an 8 -inch stud at each end for each 200 turnbuckles or fraction thereof .
3.Greater of 1 percent or 8 of the cable yield indicators produced from each mill heat .
4.2 disc springs of each size produced from each mill heat . Items to be submitted at the manufacturer's plant must be submitted with all manufacturer's plant -applied coatings.
60-4.09A(3)(c) Pipe -Type Restrainers
Submit shop drawings showing the method of grouting pipe -type restrainers.
60-4.09A(4) Quality Assurance
Bridge joint restrainer materials are inspected at the fabrication site. Notify the Engineer:
1.When materials have been delivered to the fabrication site
2.At least 10 days before starting fabrication
60-4.09B Materials
60-4.09B(1) General
Reserved
60-4.09B(2) Cable Type Restrainers
60-4.09B(2)(a) General
Cable -type restrainers consist of cables, swaged fitt ings, studs, nuts, cable yield indicators, disc springs, and, if shown, turnbuckles. Cables must be galvanized, 3/4 -inch preformed, 6 by 19, wire strand core or independent wire rope core, complying with Federal Specification RR -W-410, right regular lay, m anufactured of improved plow steel with a minimum breaking strength of 23 tons. Each swaged fitting must:
1.Be m achined from hot -rolled steel bars complying with AISI C -1035
2.Be annealed, suitable for cold swaging
3.Have a hole drilled through the head to accommodate the locking pin
4.Have the manufacturer's identifying mark stamped on the body The locking pin must be a 1/4 -inch-diameter, zinc -plated steel spring pin. The pin must keep the stud in proper position. Before galvanizing, mill a 3/8 -inch s lot for the locking pin in the stud end. Each stud must comply with ASTM A449 after galvanizing. Nuts must comply with ASTM A563, including appendix X1, except lubrication is not required. Each cable yield indicator must:
1.Be machined from hot-rolled steel bars complying with AISI C -1035
2.Be annealed, suitable for cold swaging
3.Have the heat number and manufacturer's identifying mark stamped on the end surface Disc springs must be made from steel complying with ASTM A684/A684M, Grade 10 75. Turnbuckles must be steel pipe type. Pulls for turnbuckles must consist of a swaged fitting and stud assembly. SECTION 60 EXISTING STRUCTURES Steel parts must comply with ASTM A36/A36M or A576, Grade 1030 and must not be rimmed or capped steel. Pipe sleeves must be commercial -qualit y welded steel pipe. Concrete for filling cable drum units must either (1) comply with the specifications for minor concrete or
2.be a concrete mix with a 3/8 -inch maximum combined aggregate grading and at least 675 pounds of cementitious material per cu bic yard. Elastomeric bearing pads must comply with section 51 -3.02 except pads may consist of only elastomer and laminated reinforcement is not required. PVC must be commercial quality. Bond breaker on PVC pipe must be a mortar -tight wrapping of plastic o r rubber sheet at least 0.010 inch thick. Expanded polystyrene and hardboard must comply with section 51 -2.01B(1). Neoprene sheets must comply with the specifications for neoprene in section 51 -2.04. The sheets must be smooth, free from pinholes and surfac e blemishes, and show no evidence of delamination. Closed -cell expanded neoprene material must be commercial quality and comply with the stiffness requirements in ASTM D1056 for Class SC, Grade SCE43 material or firmer.
60-4.09B(2)(b) Corrosion Protection
Reserved
60-4.09B(2)(c) Fabrication
60-4.09B(2)(c)(i) General
You are responsible for determining the required lengths of cable -type restrainers. Each swaged fitting, turnbuckle, stud, and nut assembly must develop the specified breaking strength of the cable. Machine the wall of the reduced section of the cable yield indicator such that the indicator yields at a load of from 36,000 to 38,000 pounds when tested in compression along the major axis at a test speed of at most 1/2 inch/minute. Clean and pain t disc springs the described color using a paint recommended by the manufacturer of the disc springs. Disc springs do not need to be galvanized. The minimum size of fillet welds must comply with AWS D1.1 except as follows: Minimum Fillet Weld Sizes Base metal thickness of thicker part joined
T.(inches) Minimum size of fillet weld (inches) 3/4 < T ≤ 1 -1/2 5/16 1-1/2 < T ≤ 2 -1/4 3/8 2-1/4 < T ≤ 6 1/2 6 < T 5/8 You may drill holes in steel parts after galvanizing if you repair the holes as specified for repairing damaged galvanized surfaces in section 75 -1.02B. The finish coat must match color no. 26373 of AMS -STD-595. Securely wrap each free end of restrainer -unit cables to prevent separation. Ship cable -type restrainers as complete units.
60-4.09B(2)(c)(ii) Applying Corrosion Protection
Reserved SECTION 60 EXISTING STRUCTURES
60-4.09B(3) Bar Type Restrainers
Bar-type restrainers consist of HS bars, bearing plates, couplers, anchorage devices, and incidentals. You must determine the required length of each bar -type restrainer. Bar-type restrainers must comply with the specifications for bar prestressing steel in section 50. Each anchorage device and coupler must develop the specified minimum ultimate tensile strength of the steel bar and include locking devices to prevent turning or loosening. Bearing plates must comply with ASTM A36/A36M. Elastomeric bearing pads must comply with section 51 -3.02 and must be bonded to bearing plates with adhesive complying with Federal Specification MMM -A-121. Ship each bar -type re strainer as a complete unit, including anchorage device and coupler.
60-4.09B(4) Pipe Type Restrainers
Pipe-type restrainers consist of double extra -strong steel pipe and associated hardware. Double extra -strong pipe for pipe -type restrainers must comply with ASTM A53/A53M, Grade B. Grout for bonding the pipe to the existing concrete must comply with section 60 -4.06B(2).
60-4.09C Construction
60-4.09C(1) General
Place new concrete adjacent to restrainers before installing them. Where removing and replaci ng restrainers, remove at most 50 percent of the restrainers at any joint and replace them with an equal proportion of new restrainers before subsequent removal activities. Perform all removal and replacement symmetrically about the centerline of the exist ing bridge. If paint removal or welding at connections to existing steel is not described at restrainer locations, wash loose dirt and dust from existing contact surfaces of HS bolted connections without disturbing the existing paint. Clean and paint exist ing contact surfaces of HS bolted connections that contain rust, loose paint, or other foreign substances other than dirt and dust. Cleaning and painting existing contact surfaces is change order work. Repair painted areas of existing structural steel dama ged (1) by your operations or (2) from drilling holes through existing steel members. Repairing painted areas must comply with the specifications for repairing damaged galvanized surfaces in section 75 -1.02B.
60-4.09C(2) Cable Type Restrainers
Notify the Engineer at least 2 days before tightening and setting cable -type restrainer units.
60-4.09C(3) Bar Type Restrainers
Clean and paint new metal surfaces of bar -type restrainer units after fabrication as specified for new structural steel in section 59-2, except:
1.SSPC -QP 1, SSPC -QP 2, and AISC -420-10/SSPC -QP3 certifications are not required
2.Blast -cleaned surfaces require only a single undercoat of inorganic zinc primer
60-4.09C(4) Pipe Type Restrainers
Bond pipe -type restrainers to existing co ncrete by completely filling the void between the pipe and the cored hole with grout within the limits shown. Provide filler material and seals along the sides of the pipe to prevent grout from entering the bridge hinge joints. The filler material and seal s must not restrict joint movement.
60-4.09D Payment
The payment quantity for miscellaneous metal (restrainer) does not include the weight of nonmetallic materials used in constructing the restrainers. SECTION 60 EXISTING STRUCTURES
60-4.10 Bridge Seat Extenders for Retrofits
60-4.10A General
60-4.10A(1) Summary
Section 60 -4.10 includes specifications for fabricating and installing bridge seat extenders . Bridge seat extenders must comply with the specifications for miscellaneous bridge metal in section 75 -3.
60-4.10A(2) Definitions
Reserved
60-4.10A(3) Submittals
Submit a work plan showing the method of grouting pipe seat extenders to prevent grout from entering the hinge area .
60-4.10A(4) Quality Assurance
Inspect b ridge seat extender materials at the fabrication site. Notify the Engineer:
1.When materials have been delivered to the fabrication site
2.At least 10 days before starting fabrication
60-4.10B Materials
60-4.10B(1) General
Reserved
60-4.10B(2) Pipe Seat Extenders
Pipe seat extenders must consist of double extra -strong steel pipes, HS threaded rods, nuts, and washers. Double -extra strong steel pipe must comply with ASTM A53/A53M, Grade B. HS threaded rods, nuts, and washers must comply with section 55 -1.02D(1). Galvanize double -extra strong steel pipe under section 75 -1.02B. After galvanizing, any alterations resulting in new exposed surfaces, including holes or cut ends, must be coated as specified for repairing damaged galvanized surfaces under section 75 -1.02B. Grout for bonding the pipe to the cored hole must comply with section 60 -4.06B(2). Any filler material s or seals must not restrict joint movement.
60-4.10B(3) Slab Bridge Seat Extenders
Slab bridge seat extenders must consist of steel plates, support tubes, bolts, bars, nuts, washers, pins, and elas tomeric bearing pads. Slab bridge seat extenders must comply with section 55. Elastomeric bearing pads must comply with section 51 -3.02. The support tubes must comply with ASTM A500 /A500M , Grade B. Galvanize seat extende rs under section 75 -1.02B . After gal vanizing, any alterations resulting in new exposed surfaces, including holes or cut ends, must be coated as specified for repairing damaged galvanized surfaces under section 75 -1.02B. Epoxy mortar must consist of a mixture of epoxy binder and aggregate. The epoxy mortar must comply with section 95 -1.02C . The mix proportions of epoxy mortar must be 1 -part binder to 1 -part aggregate by volume. Aggregate must consist of a combination of 1 -part material passing the no. 30 sieve and 3 -parts material passing the no. 20 sieve.
60-4.10C Construction
60-4.10C(1) General
Reserved SECTION 60 EXISTING STRUCTURES
60-4.10C(2) Pipe Seat Extenders
Reserved
60-4.10C(3) Slab Bridge Seat Extenders
Place e poxy mortar under section 95 -1.03. Place e lastomeric bearing pads under section 51 -3.02C. Bond e lastomeric bearing pads to steel support tubes with adhesive complying with Federal Specification MMM -A-121.
60-4.10D Payment
The payment quantity for seat extender does not include the w eight of nonmetallic materials used in constructing the seat extenders .
60-4.11 Replace Access Doors
60-4.11A General
60-4.11A(1) Summary
Replacing access doors includes (1) removing an existing recessed access door with hinges, and (2) installing a new access door with frame.
60-4.11A(2) Definitions
Reserved
60-4.11A(3) Submittals
Submit 3 copies of access door assembly shop drawings for each location requiring a new access door assembly. Shop drawings must include:
1.Name of fabricator
2.Field measurement of the height, width, and wall thickness
3.Details for temporary metal covers including connections or fasteners to be used
60-4.11A(4) Quality Assurance
Reserved
60-4.11B Materials
Materials for access door assemblies and associated hardware must comply with section 75 -3.02. Access door assemblies consist of:
1.Sheet steel door with stiffeners
2.Lock cover and hasp
3.Door frame Fabricate access door assemblies in a sho p. Do not punch, cut, or weld assemblies in the field, except for tack welds of the expansion anchors. Galvanize access door assemblies and hardware under section 75 -1.02B. After galvanizing, the access door assemblies and hardware must be free of fins, ab rasions, and rough edges. Repairs to galvanized surfaces must comply with section 75 -1.02B.
60-4.11C Construction
Verify existing access opening sizes before fabricating access door assemblies. Where the existing door or cover is unusable after opening, f urnish and install a temporary metal cover over the opening. This work is change order work. SECTION 60 EXISTING STRUCTURES If the existing access opening is smaller than the opening size shown on the plan, enlarge the opening by saw-cutting full -depth to the dimension shown. Cut existi ng reinforcement 1 inch below the surface. Clean and patch the holes under section 51 -1.03F(2). This work is change order work. Remove the existing steel cover . Clean and prepare the concrete surface surrounding the existing frame. Refinish concrete edging so the new frame is flush with the existing frame. Furnish a padlock for the access door assembly until Contract acceptance. Do not leave any access opening uncovered and unsecured at the end of a work shift.
60-4.11D Payment
Not Used
60-4.12 60-4.15 Reserved
60-5 Abandoning Structures
60-5.01 General
60-5.01A General
60-5.01B Materials
Not Used
60-5.01C Construction
Not Used
60-5.01D Payment
Not Used
60-5.02 Abandoning Pe Destrian Undercrossings
Reserved
60-5.03 60-5.10 Reserved
60-6 60-10 Reserved
Source: California Standard Specifications, 2024 Edition. Pages 919–950 of 1,372.