458BRIDGE DECK JOINTS

458-1Description

Furnish and install bridge deck joints of the types and at the locations shown in the P lans. This Section covers the following types of joints: Poured Joint Poured Joint with Backer Rod System Strip Seal Joint System Modular Joint

458-2Materials

458-2.1General: Transport, store and prepare all joint materials and components for all

joint types as per the manufacturer’s recommendations .

458-2.2Poured Joint: Furnish a Type D silicone seala nt material meeting the

requirements of Section 932 that is listed on the Approved Product List ( APL).

458-2.3Poured Joint with Backer Rod System: Furnish poured joint with backer rod

systems consisting of Type D silicone sealant material, foam backer rods, sidewalk cover plates (as required) and all associated miscellaneous components. The Type D silicone sealant material used in the system shall be listed on the APL and meet the requirements of Section 932.

458-2.4Strip Seal Joint System: Furnish strip seal joint systems that are listed on the

APL. Manufacturers seeking evaluation of their product for the APL shall submit an application in accordance with Section 6. Design documentation showing the expansion joint system shall include inst allation details and temporary or sacrificial support brackets, bolts, clamps, etc. that are compatible with decks constructed with or without block -outs. Furnish joint systems consisting of watertight steel edge rails, strip seal glands and all associated miscellaneous components. 458-2.4.1 Strip Seal Joint Systems with elastomeric glands: Product must meet the requirements of ASTM D5973 and Standard Plans, Index 458-100. Obtain the strip seal elastomeric glands from the edge rail manufacturer. 458-2.4.2 Strip Seal Joint Systems with silicone glands: Product must meet the requirements of Standard Plans, Index 458 -100. Adhesives must be supplied by the same manufacturer as the glands and must meet ASTM C793 with no cracking, ozone chalking or degradation .

458-2.5Modular Joint: Furnish modular joints meeting the requirements of this Section

Submit manufacturer certification that modular joint components meet the following material requirements in Table 458-1.

624 FY 2023-24 Return to Table of Contents Table 458-1 Component Material Requirements Solid Separation Beams, Steel Extrusions, Support Bars, Plate and Milled Steel Shapes ASTM A588 or ASTM A572, Grade 50 Box Seals ASTM D3542 Strip Seals ASTM D5973 Seal Adhesive ASTM D4070 Stud Shear Connectors and Threaded Studs ASTM A108 Stainless Steel Sliding Plates ASTM A240, Type 316 PTFE Sliding Surface ASTM D4895 *Provide seals with hardness Type A durometer equal to 55 (plus or minus 5) by ASTM D2240.

Supply test results from the manufacturer verifying the maximum coefficient of friction between mating surfaces. Testing must be performed by an independent testing laboratory according to the manufacturer’s stated precompression values for the system to a minimum of two million cycles. Maximum allowed coeffici ent of friction is 0.10. Bond PTFE (polytetrafluorethylene) using a heat cured, high temperature epoxy capable of withstanding temperatures of minus 40°F to plus 250°F. For springs, bearing, and equidistance devices (i.e. control springs), use the same material composition and formulation, manufacturer, fabrication procedure and configuration as those used in the prequalification test. Components manufactured from polyurethane compounds are not permitted.

458-2.6Sidewalk Cover Plates: Furnish slip res istant, random hatch matrix or suitable

pattern, galvanized steel sidewalk cover plates fabricated from steel meeting the requirements of ASTM A36 or ASTM A709, Grade 36 or 50. Do not use diamond plate or surface applied slip resistant tapes, films, nonmet allic coatings or other similar materials. Fabricate cover plates in accordance with Standard Plans, Indexes 458-100 and 458 -110. After shop fabrication, hot -dip galvanize cover plates in accordance with Section 962. Galvanized sidewalk cover plates shall have a minimum coefficient of friction on the top surface of 0.8 in dry condition, and 0.65 in a wet condition, as determined by ASTM F1677-05 or ASTM F1679-04. Furnish flat head stainless steel sleeve anchors in accordance with ASTM F593 Group 1 Alloy 304 for attaching sidewalk cover plates. Install sleeve anchors in accordance with the manufacturer’s instructions.

458-3Calculations and Shop Drawings

458-3.1All Joint Types (with the exception of Poured Joints): Submit shop drawings

in accordance with Section 5 for any applicable joint system supplied. For format and required details, follow the AASHTO/NSBA Steel Bridge Collaboration “Guideline for Shop Detail Drawing Presentation”. The following information must be included on the shop drawings:

address where the fabrication is performed.

proper width settings for a minimum 100°F temperature range. Shop drawings that are submitted without this information will be returned without review.

the joint model number and joint movement range. 625 FY 2023-24 Return to Table of Contents

458-3.2Sidewalk Cover Plates: Submit shop drawings for sidewalk cover plates

showing all materials, project specific details and dimensions. The submittal must include a certification from the manufacturer that the sidewalk cover plates m eet the minimum coefficient of friction requirements.

458-3.3Strip Seals: Provide the APL number in the shop drawings

458-3.4Modular Joints: When support boxes are supported by the deck or abutment,

detail in the shop drawings a minimum of 2 inches between the bottom surfaces of the joint elements and the deck blockouts to allow easy placement of concrete and allow for proper consolidation of concrete under and around all parts of the joints. Detail in the shop drawings at least 6 inches of clear space between the support boxes or anchorages on the ends of support boxes and the periphery of the blockout to permit placing of concrete. Submittal of shop drawings must include a manufacturer’s installation manual in accordance with this Section. Include design calculations, signed and sealed by a Professional Engineer licensed in the State of Florida, confirming that all load bearing components are in conformance with the requirements of this Section.

458-4Fabrication and Installation

458-4.1General: Install the joint in accordance with the specific requirements of this

Section, the plan details, the Standard Plans , and the manufacturer’s installation instructions for the particular type of expansion joint to be installed.

458-4.2Poured Join t: Install the joint at the locations and in accordance with the details

shown in the Plans and the manufacturer’s recommendations.

458-4.3Poured Joint with Backer Rod System:

458-4.3.1 Casting Joint Opening : When casting the bridge deck, approach slab or raised sidewalk adjacent to the expansion joint at temperatures other than 70 °F, adjust the joint opening ( Dim. A as shown in Standard Plans, Index 458-110) at 70°F by the amount of the adjustment per 10 °F shown in the Structures Plans, Poured Expansion Joint Data Table. For temperatures above 70 °F, decrease the opening . For temperatures below 70 °F, increase the opening. 458-4.3.2 Installation of Poured Joint System: After deck profiling, grinding, and grooving operations are complete, i nstall poured joint with backer rod in accordance with the manufacturer ’s recommendations, when the joint opening is plus or minus 1/4 inch of the design joint opening (Dim A at 70°F) shown in the Structures Plans, Poured Expansion Joint Data Table. The minimum openi ng must not be less than 1 inch at the time of installation. Place poured joint material only when the ambient temperature is between 55 °F and 85°F and is expected to rise for the next three hours minimum to provide for adequate joint opening and compression of the poured joint material during curing.

458-4.4Strip Seal System:

458-4.4.1 Glands for Joint Seal : Seals must be continuous heavy duty bridge deck glands sized in accordance with the manufacturer’s recommendations, to perform satisfactorily for the opening range shown. Minimum movement classification is 4 inches. 458-4.4.1.1 Elastomeric Gland Seals: Shop vulcanization is restricted to use on horizontal turns on skewed bridges at upturn ends where the horizontal turn angle is greater than 35 degrees. Field vulcanization is not permitted. 626 FY 2023-24 Return to Table of Contents 458-4.4.1.2 Silicone Gland Seals: Meet the following requirements in Table 458 -2: Table 458-2 Silicone Gland Seal Requirements Property Test Method Range Durometer (Shore A) ASTM D2240 55 +/- 5 Elongation ASTM D412 350% (min) Tensile ASTM D412 550 psi (min) Tearing (die B ppil) ASTM D624 80 lb/in (min) Compression Set ASTM D395 30% max at 350o F Temperature Range -60o F to 450o F Specific Gravity 1.51

458-4.4.2 Edge Rail Fabrication:

accordance with ASTM A709, Grade 36, 50 or 50(W). Furnish edge rails with a minimum mass of 19.2 lb/ft excluding studs, a minimum height of 8 inches, a minimum thickness of 1/2 inch and a maximum top surface (ridings urface) width of 2 inches. Edge rails manufactured from built up pieces must have continuous longitudinal welds. Built -up member connections directly supporting wheel loads must use complete penetration welds.

end-weld anchor studs with complete fusion. Anchor studs may be piggy backed to achieve required lengths.

ANSI/AASHTO/ AWS D1.5. Do not wel d to surfaces in contact with the elastomeric seal or the top surface (riding surface) except as shown in the shop splice detail . Do not weld inside seal cavity.

in place, integra l to the edge rail assemblies by full length welds or extruded sections . Splices in an individual joint are only permitted where a construction joint is specifically required by the Plans, joint segment length exceeds 50 feet, or approved by the Engineer i n writing. Shop splice sections of edge rail to obtain the required length by partial penetration double V -groove welds on prepared beveled edges and seal welds as shown in the shop splice detail. Weld all around the joint as far as practical to achieve a watertight seal. Do not use short pieces of edge rail less than 6 feet 0 inches long unless required at curbs, sidewalks or phase construction locations.

are capable of resisting shipping, handling and construction forces without damage to the edge rail assemblies or galvanized coating and are adjustable to account for variable temperature settings. Do not use temporary or sacrificial support brackets, bolts, clamps, etc. between the faces of the edge rails.

location and direction of stationing. 458-4.4.3 Installation: 627 FY 2023-24 Return to Table of Contents

after deck planing in accordance with the manufacturer’s instructions. When installed after deck

planing and grinding, install the edge rail assemblies in the block-outs on a profile tangent

between the ends of the deck and/or approach slab to within a plus 0 inch and minus 1/4 inch

variation. When installed before deck planing, install the edge rail assemblies 3/8 inches, plus or

minus 1/16 inch, below the top surface of the deck or approach slab to compensate for concrete

removal during planing and grinding.

sacrificial brackets as required. For phased construction, install edge rail assemblies in a given

subsequent phase to align with those installed in an adjacent prior phase after deflection and

rotation due to deck casting of adjoining spans has occurred.

adjust the opening of the joint (Dim. A as shown in Standard Plans, Index 458-100) by the

amount of the adjustment per 10°F shown in the Structures Plans, Strip Seal Expansion Joint

Data Table. For temperatures above 70°F, decrease the opening. For temperatures below 70°F,

increase the opening.

exposed in the completed structure. Do not weld expansion joint components to or electrically

ground to reinforcing steel or structural steel. Seal field butt joints and empty shipping and

erection holes with caulk before placing deck concrete.

the manufacturer’s recommendations. Provide temporary blocking material in the edge rail seal

cavities to prevent concrete intrusion during deck pour and finishing.

that span across the joint after initial set of concrete, but not more than two hours after

conclusion of concrete placement.

joint form material and blocking material prior to installing glands. Field install glands in

accordance with manufacturer’s recommendations.

458-4.5Modular Joints

458-4.5.1 Fabrication: Perform all steel fabrication in accordance with the

requirements of Section 460.

After fabrication, hot-dip galvanize all non-stainless steel metal surfaces in

accordance with Section 962.

Joint systems must be designed in accordance with the latest edition of

AASHTO LRFD Bridge Design Specifications or as required by the Contract Documents.

Supply joint systems for which identical full-size specimens have been subjected to full life-

cycle fatigue testing. Obtain all joint system components from the same manufacturer, fabricated

at their approved corporate facilities, using subcomponents meeting the testing requirements of

this Section.

Except for sliding plates, provide all load bearing structural steel

components with a 3/8 inch minimum thickness in any direction. Construct edge rails consisting

of a monolithic steel shape with a machined or extruded retainer cavity. Multiple component

welded steel shapes to achieve a final member cross section or seal retainer cavity are not

permitted. Attach separation beams to individual support bars with a complete joint penetration

weld. 628FY 2023-24Return to Table of Contents

Support each separation beam with a dedicated support bar connected by a

complete joint penetration welded connection. Use of bolted connections, yokes, or other means

to directly attach separation beams to support bars is not permitted. Maintain equal spacing

between separation beams at all stages of movement.

Contain support bars with bearings capable of transferring all imposed

loads to the structure and allow the support bar to freely move within the limits of the expansion

joint.

Fabricate a full length modular joint system as one piece. Only a minimal

number of splices in an individual joint may be permitted where a construction joint is

specifically required by the Plans, joint segment length exceeds 50 feet, or approved by the

Engineer in writing.

When phased construction is permitted or required by the Contract

Documents, fabricate each segment to exactly fit that portion of superstructure, including

sidewalks, under construction in each specific phase. Connect segments with a bolted splice to

ensure continuity. Fit segments with temporary seals. Lubricant adhesive is not required for

temporary seals. Submit watertight seal details for the splice. Shop inspection will be conducted

at the discretion of the Engineer in accordance with Article 5-6.

Fabricate final seal assembly as one single, continuous component.

Splicing of seals in the field is not permitted.

Provide lifting devices and devices to maintain the preset opening of the

joint at a uniform spacing of not greater than 15 feet along the length of the joint. Provide at least

three of these preset opening devices per joint segment. Provide lifting and preset opening

devices that function and then are removed without damaging the modular joint system

assemblies or galvanized coating.

Prior to shipment, preset the joint opening in accordance with the joint

opening as shown in the Plans at 70°F.

Prior to installation, place the centerbeam/support bar assembly on a flat

surface to verify the support bars lay in a single plane, with no part of the bottom of any support

bar exceeding 0.25 inches off the surface. The subassembly may be straightened. No more than

three attempts may be made to heat-straighten the subassembly.

Polish stainless steel sliding surfaces to an 8 μ-inch mirror finish.

458-4.5.2 Installation: Clean any metal surface component exhibiting surface

rust and field metalize in accordance with Section 562. Replace any component exhibiting pitting

and/or section loss with a new component.

Install the joint system in strict compliance with the manufacturer’s

instructions in the shop drawings and as directed by the manufacturer’s installation technician.

458-4.5.2.1 Manufacturer’s Installation Manual: Submit the

manufacturer’s installation manual at least two weeks prior to installation activities, containing

complete and detailed installation instructions for the modular expansion joint supplied by the

Contractor. The manual must include step-by-step installation instructions and all related

manufacturer’s recommendations, including bridge deck pouring sequence, restraints, finishing,

etc., for successful installation and long term operation and serviceability of the joint.

458-4.5.2.2 Manufacturer’s Installation Technician: Provide for a

manufacturer’s installation technician, under the direct employ of the manufacturer, to be on the

jobsite prior to the first joint installation and in sufficient time to train the Contractor’s joint

installation crews using the shop drawings and the manufacturer’s installation manual. The 629FY 2023-24Return to Table of Contents

manufacturer’s installation technician must remain on the jobsite and be present for all modular

joint installation activities for a minimum of the first two joints for each of the Contractor’s

installation crews. The manufacturer’s installation technician will submit written certification to

the Engineer that the Contractor’s installation process follows the requirements outlined in the

manufacturer’s installation manual.

458-4.5.2.3 Field Inspection: The Engineer will inspect the joint system

for proper alignment, complete bond between neoprene gland seal and steel, and proper stud

placement and effectiveness.

Bends or kinks in the joint system steel are not allowed except as

necessary to follow roadway grades. Straightening of any bends or kinks in the steel, whether

intentional or inadvertent, is not allowed. Any joint system exhibiting bends or kinks will be

rejected, removed from the jobsite, and replaced by a new joint system. Match joint system to the

finished roadway profile and grades before final acceptance.

Restore bond of any neoprene gland seal found not fully bonded to

steel.

Visually inspect all stud welds. Test a minimum of 10% of the

total number of stud welds at the discretion and direction of the Engineer. Any stud found to not

have a complete end weld (as evidenced by a ringing sound when struck by a hammer) will

require replacement. Any stud located more than one inch in any direction from location shown

in the shop drawings will require removal and a new stud placed in the proper location.

458-4.5.2.4 Width: For installation at temperatures other than 70°F, adjust

opening of the joint as shown in the Contract Documents by amount of adjustment per 10°F

shown in the Contract Documents. For temperatures above 70°F, decrease the opening. For

temperatures below 70°F, increase the opening. Release all support brackets as the concrete is

being placed and no later than when the concrete takes initial set.

Remove opening devices immediately after the concrete is placed.

458-4.5.2.5 Permanent Seals: When phased construction is necessary,

remove temporary neoprene seals and replace with full width permanent seals after joint system

is completely installed over full width of structure, including sidewalks.

Clean (SSPC-SP6) all metal surfaces which will be in contact with

permanent seals to visual standard CSP6 as defined by SSPC Vis 1-89.

458-4.5.2.6 Final Placement: After modular joint system has been set to

its final line and grade, fill any deck joint blockouts with Class II (Bridge Deck) concrete or as

specified in the Plans. Prepare contact surfaces in accordance with the same procedure described

in this Section. Finish the uppermost surface of concrete placement in accordance with

requirements of 400-15, except that machine finishing is not required. Unless otherwise noted in

the Plans, include the cost of the pourback in the unit bid price of superstructure concrete.

Construction loads are not allowed on the modular joint for

72 hours after complete installation unless approved by the Engineer. In the event it is necessary

to cross the modular joint before the 72 hour prohibition, bridge over the joint in a manner

approved by the Engineer.

458-4.5.3 Acceptance: Acceptance of fabricated joint systems will be based on

the Engineer’s visual inspection at the jobsite and in accordance with requirements of this

Section.

Submit certified mill test reports to the Engineer for all steel used to

fabricate the joint system. 630FY 2023-24Return to Table of Contents

458-4.5.3.1 Watertight Integrity Test: Test full length of joint system for

watertight integrity in accordance with this Section, no more than five working days after each

joint system installation is completed. In case of phased construction, perform this test after the

full length of joint is installed (after all applicable phases). For the first two joints, perform the

watertight integrity test and inspection in the presence of the manufacturer’s installation

technician and the Engineer. For all remaining joints, perform the watertight integrity test and

inspection in the presence of the Engineer.

Cover full length of joint with either water ponded to a minimum

1/2 inch depth, or continuously flowing water directly over full plan area of joint for a 15 minute

minimum duration. Inspect underdeck surfaces beneath the joint for any evidence of dripping

water or moisture for the 15 minute duration of water application and for 45 minutes after water

supply is removed. Watertight integrity of joint system is interpreted as absolutely no free

dripping water or moisture on underdeck surfaces beneath joint. Document date, time, and

location of joint inspections and submit the report to the Engineer.

Repair joint integrity at every location exhibiting free dripping

water or moisture identified during the watertight integrity test and subsequently retest, subject to

same conditions and consequences as the initial test. Retest and repair until joints pass the

watertight integrity test.

458-5Method of Measurement

The poured joint without backer rod will be incidental to the concrete work and included

in the cost of the concrete. Poured joints with backer rod, strip seal joints, and modular

expansion joints will be the plan quantity length of each type of joint constructed and accepted.

458-6Basis of Payment

458-6.1Basic Items of Joints. The Contract unit price per foot for joints will be full

compensation for all work and materials necessary for the complete installation. Such price and

payment will include, but not be limited to, the following specific incidental work:

out or deck joint gap.

construction or installation techniques.

necessary for ensuring proper alignment and positioning of the joint relative to the bridge deck.

necessary repairs and retesting.

458-6.2Payment Items: Payment shall be made under:

Item No. 458 - 1- Bridge Deck Expansion Joint - per foot. 631FY 2023-24Return to Table of Contents BITUMEN COATING AND POLYETHYLENE SHEETING ON CONCRETE PILES

459-1Description

Furnish and apply bituminous coating and primer, or install polyethylene sheeting and lubricant to prestressed concrete piles.

459-2Materials

459-2.1Bituminous Coating: Use an asphalt type bituminous coating meeting the

requirements of Section 916, with a minimum viscosity (at 140ºF) of 3,000 poises and a maximum of 1,000 poises. Apply bituminous coating uniformly over an asphalt primer.

459-2.2Prime r: Meet the requirements of ASTM D41

459-2.3Polyethylene Sheeting: Use polyethylene sheeting that is 6 mils thick and is

clean, new and has a smooth surface.

459-2.4Lubricant: Use a lubricant between the two layers of sheeting that is either a

vegetable oil or other approved environmentally and functionally acceptable lubricant.

459-3Construction Requirements

Before surfaces are coated with bitumen, dry and thoroughly clean them of dust and loose materials. Do not apply primer or bitumen in wet weat her or when the temperature is below 65ºF. Apply the primer to the surfaces and allow it to dry completely before applying the bituminous coating. Apply primer uniformly at the quantity of 1 gal/100 ft2 of surface. Apply bitumen uniformly at a temperatur e of not less than 300ºF, or more than 350ºF, and apply either by mopping, brushing, or spraying at the project site. Completely fill all holes or depressions in the concrete surface with bitumen. Apply the bituminous coating to a minimum dry thickness of 1/8 inch, but not less than 8 gal/100 ft2. Store bitumen coated piles before driving, and protect piles from sunlight and heat. Ensure that pile coatings are not damaged during storage, hauling, or handling. Take appropriate measures to preserve and maint ain the bitumen coating. At the time of pile driving, ensure that the bitumen coating has a minimum dry thickness of 1/8 inch. If necessary, recoat the piles, at no cost to the Department, to comply with the requirements of this Section. Ensure that all s urfaces to be wrapped with polyethylene sheeting are dry and thoroughly cleaned of dust and loose materials. Place the sheeting on the pile to the limits shown on the Plans. Wrap the pile with a minimum of 2 1/4 wraps of sheeting. Apply a uniform coating of a lubricant between the first and the second layers. Ensure that this coating fully covers the entire surface of the first layer of sheeting. Once the pile has been wrapped with the minimum of two and one -quarter wraps of sheeting, secure the sheeting w ith tape or other means that does not damage the sheeting or restrict its movement. Do not place any tape or other material other than the lubricant between the first and second layers of sheeting. Protect the sheeting from construction damage. Where sheeting has been damaged, completely remove the damaged sheet of polyethylene and replace it, at no cost to the Department, as directed by the Engineer. Where the sheeting will not wrap the specified limits of the pile in one sheet, overlap the previous sheet with each subsequent sheet by 12 inches. 632 FY 2023-24 Return to Table of Contents