500Concrete Structures

500.1General Description

This work consists of manufacturing and using Portland cement concrete to construct structures. See the Contract Plans for the specified color and locations for placing integrally colored concrete. 500.1.01 Definitions General Provisions 101 through 150. 500.1.02 Related References

ASTM A 653/653M ASTM A 924/924/M ASTM C 685 ASTM C 979 ASTM D 260, Type I or Type II AASHTO C 309 AASHTO C 171 AASHTO M 194M/M 194 AASHTO R 39 AASHTO T 126 AWS D 1.5 621 621 621 621 621 621

SOP 10 SOP 17 SOP 46 American Iron and Steel Institute Specification for the Design of Cold Formed Steel Structural Members Federal Specification TT-P-641d, Type II Georgia Standards 4941B and 4949 Series QPL 10 QPL 17 GDT 134 DOT 525 500.1.03 Submittals

The Contractor is responsible for all concrete mix designs. Ensure that concrete mixes contain enough cement to produce workability within the water-ratio specified in Table 1—Concrete Mix Table, below. Design concrete mixes that meet the requirements of the Table 1—Concrete Mix Table, below. The Office of Materials and Testing will determine the concrete properties using the applicable method in Section 500 of the Sampling, Testing, and Inspection Manual. TABLE 1—CONCRETE MIX TABLE English Class of Concrete

Aggregate Size No. (1 & 6) Minimum Cement Factor lb./yd3 Maximum Water/ Cement ratio lbs./lb. (5) Slump Acceptance Limits (in) Lower - Upper (3 & 7) Entrained Air Acceptance Limits (%) Lower - Upper Minimum Compressiv e Strength at 28 days (psi) “AAA” 67,68 675 0.44 2 4 2.5 6 5000 “AA1” 67,68 675 0.44 2 4 2.5 6 4500 “D” 57, 67 650 0.445 2 4 3.5 7 4000 “AA” 56,57,67 635 0.445 2 4 3.5 7 3500 “A” 56,57,67 611 0.49 2 4 2.5 (3) 6 3000 “B” 56,57,67 470 0.66 2 4 0 6 2200 “CS” 56,57,67 Graded Agg.* 280 1.4 - 3½ 3 7 1000 (4) 622 622 622 622 622 622

Metric Class of Concrete

Aggregate Size No. (1 & 6) Minimum Cement Factor kg/m3 Maximum Water/ Cement ratio kg/kg (5) Slump Acceptance Limits (mm) Lower - Upper (3 & 7) Entrained Air Acceptance Limits (%) Lower-Upper Minimum Compressive Strength at 28 days MPa) “AAA” 67,68 400 0.44 50 100 2.5 6 35 “AA1” 67,68 400 0.44 50 100 2.5 6 30 “D” 57,67 385 0.445 50 100 3.5 7 28 “AA” 56,57,67 375 0.445 50 100 3.5 7 25 “A” 56,57,67 360 0.49 50 100 2.5 (3) 6 20 “B” 56,57,67 280 0.66 50 100 0 6 15 “CS” 56,57,67 165 1.4 - 90 3 7 7 (4) Graded Agg.* NOTES:

granulated iron blast furnace slag as provide for in Subsection 500.3.04.D.5.

(7 MPa) + 0.18 R*. Compressive strength will be determined based upon result of six cylinders prepared and tested in accordance with AASHTO T 22 and R 39. * Where R = Difference between the largest observed value and the smallest observed value for all compressive strength specimens at 28 days for a given combination of materials and mix proportions prepared together.

are used.

is used.

to 7.0%. Submit all concrete mix designs to the Office of Materials and Testing (OMAT) for review. The Department will approve mixes that contain materials from approved sources and produce concrete that meets these Specifications. Submit concrete mix design proportions for approval by one of the following methods:

When requesting approval of specific concrete mix design proportions for classes of concrete, include the following information: • Source of each material • Apparent specific gravity of the cement and the fly ash, if used • Bulk specific gravity (saturated surface dry) of each aggregate • Percent absorption of each aggregate • Amount of each material required to produce a cubic yard (meter) of concrete 623 623 623 623 623 623

• Proportions of admixtures per cubic yard (meter) of concrete and any use limitations • Proposed slump and air content of the design • Evidence that the proposed mixture complies with Subsection 500.1.03, . Concrete mix designs that do not have a proven performance record and have not been used by the Department must meet minimum laboratory strength requirements.

Get approved concrete mix designs from authorized ready-mix concrete plants. Ready-mix concrete plants approved according to Laboratory Standard Operating Procedure “Quality Assurance for Ready Mix Concrete Plants in Georgia” (SOP 10) are authorized to submit concrete mix designs for approval. See QPL 10 for a list of approved plants.

Use laboratory-designed concrete mix proportions from either of the following sources:

Request these mixes in writing from the State Materials and Testing Engineer. Request specific classes of concrete and specify the source of ingredients.

mix that meets requirements in the Table 1—Concrete Mix Table above. The laboratory will establish proportions for strength and workability under laboratory conditions.

Have the concrete plant transmit delivery tickets (DOT Form 525) with each load of concrete delivered to the work site. Give the Engineer one of these delivery tickets. Ensure that the following information is on the delivery ticket: • Project designation • Date • Time • Class and quantity of concrete • Actual batch proportions • Free moisture content of aggregates • Quantity of water withheld • Concrete mixing revolutions If available forms do not provide the required information, ask the Engineer to provide one.

The Engineer may require detailed formwork plans for review. If so prepare the formwork plans and submit them to the Engineer. In no case will the Contractor be relieved of responsibility for the formwork plans. When constructing permanent steel bridge deck forms, submit bar support details and types to the Department for approval before placing the deck form reinforcement.

Submit, for review by the Engineer, detailed falsework plans for spans under which traffic flows. The Engineer may require plans for spans that do not accommodate traffic. 624 624 624 624 624 624

Submit fabricators’ shop and erection drawings to the Engineer for review and approval. Indicate the following in the drawings: • Grade of steel • Physical and section properties for permanent steel bridge deck form sheets • Locations where the forms are supported by steel beam flanges subject to tensile stresses

Before hauling starts on new bridges, submit the following information for each vehicle: • Weight on each axle, empty • Weight on each axle, fully loaded • Center-to-center distances of axles • Center-to-center distances of wheels measured parallel to each axle

Secure the Engineer’s approval of a “Cold Weather Concrete Curing and Protection Plan” for bridges and structures. Emphasize protection for the underside of bridge decks when using metal forms and include the protection procedures to be used. Protection procedures shall keep the concrete above 50 °F (10 °C) for 72 hours after placement and above freezing for 6 days after placement. Choose the protection method from Table 2 based on the expected temperature within 48 hours after concrete placement. The contractor shall provide a suitable curing box for structural concrete to protect the cylinders. The box may be constructed of plywood and lined with insulation or a commercially made device. TABLE 2—COLD WEATHER PROTECTION Protection Procedure Expected Temperatures Within 48 Hours Heated enclosures Below 25 °F (-4 °C) Commercial blankets Below 25 °F (-4 °C) Batt insulation Below 25 °F (-4 °C) Heavy-duty polyethylene 25 °F (-4°C) or above

Submit to the Engineer the following:

and required dosage rate. Submittals are for general verification of color. 625 625 625 625 625 625

500.2Materials

Ensure that materials meet the Specification requirements of Table 3: TABLE 3—MATERIALS SPECIFICATIONS Material Section Coarse Aggregate (1) 800.2.01 Fine Aggregate Size No. 10 801.2.02 Damp proofing or Waterproofing Material (Bituminous) 826.2.01 Portland Cement (2) 830.2.01 Portland-Pozzolan Cement (2) 830.2.03 Admixtures: Air-Entraining Admixtures 831.2.01 Retarding Admixtures 831.2.02 Water Reducing Admixtures 831.2.02 Granulated Iron Blast-Furnace Slag 831.2.03.A.3 Fly Ash 831.2.03.A.1 Curing Agents 832 Joint Fillers and Sealers 833 Special Surface Coating 836 Linseed Oil 870.2.06.A.1&2 Mineral Spirits 870.2.06.A.4 Water 880.2.01 Graded Aggregate (3) 815.2.01 Graffiti Proof Coating 838.2.01 Concrete used in Bridge Construction 500.3.04.F

bridge structures. When using limestone or dolomite, use Class A coarse aggregate.

air-entraining cement.

(2.00 mm) sieve. Construct bridge sections containing duct enclosures for stressing tendons using concrete with a maximum stone size of No. 7. Use concrete manufactured at plants that qualify as approved sources according to the Standard Operating Procedure for Ready Mix Concrete (SOP 17). See QPL 10 for a list of approved plants. Use colored concrete additive made with pure, concentrated mineral pigments especially processed for mixing into concrete and complying with ASTM C 979. 626 626 626 626 626 626

If adding color additives to the mix at the jobsite, furnish color additives in pre-measured Mix-Ready disintegrating

bags to minimize jobsite waste.

Do not use accelerator admixtures containing calcium chloride in colored concrete mix.

500.2.01 Delivery, Storage, and Handling

Stockpile aggregate as follows:

contaminated, or degrade. The Engineer may reject improperly formed stockpiles.

Operate aggregate handling equipment carefully to minimize segregation, breaks, spills, contamination, and

mixing of the sizes and types of aggregates.

Store cement as specified below. Reject all caked, lumpy, or contaminated cement.

Use bulk cement unless the Engineer allows bag cement to be used.

Store bulk cement in bins or silos designed for this purpose. Provide moisture-proof storage containers with a

mechanism that allows cement to flow freely from the discharge opening.

Store and use cement of different brands and types, or from different mills separately.

Carefully store and dispense admixtures as recommended by the manufacturer to prevent contamination.

Handle and place concrete according to the following:

Ensure that concrete reaches its final position in the forms within one hour after adding the cement to the

aggregates.

If retarders or water reducers are used, the allowable time limit increases to 1-1/2 hours. Test concrete

immediately for acceptance tolerances before placing in forms using limits established in Table 1—Concrete

Mix Table.

After delivering the concrete to the job site or the staging area at the site or after mixing the concrete at the

site, transport it carefully to the placement point to prevent excessive slump loss or segregation. Use any of

the following equipment:

• Buckets

• Buggies

• Pumps

• Other approved means

Store forms off the ground. 627627627627627627

Except as noted below, the applicable portions of Subsections 507.2.01, “Delivery, Storage, and Handling,”

507.3.05.A, Prepare Bearing Areas, 507.3.05.B, Erecting PSC Bridge Members, and 507.3.05.D, “Concrete Finish,

shall govern.

Handle precast, non-prestressed units as follows:

(30 MPa).

Comply with manufacturer’s instructions. Deliver to site or batch plant in original, unopened packaging. Store

color additives in dry conditions.

500.3Construction Requirements

500.3.01 Personnel

Provide enough supervision, personnel, and skilled workers to do the following:

Minimum Placement Rates or as required by the Plans.

Volumetric proportioning requires that the operator be certified by the Office of Materials and Testing. The

volumetric truck may be approved on a per project basis or listed on the Qualified Products List (QPL-100).

500.3.02 Equipment

Do not use delivery, conveyance, or vibratory units that leak grout, water, oil, or gas.

Provide enough equipment, tools, and materials to properly produce, place, and finish concrete in each pour unit

according to the Subsection 500.3.05.P, Table 5—Minimum Placement Rates or as required by the Plans.

The Engineer may prohibit equipment that delays concrete placement.

When concrete ingredients are proportioned volumetrically, equipment needs to be listed on QPL-100 or obtain

the Engineer’s approval for the equipment and its calibration and operation.

Ensure the following:

• The equipment meets the specifications in ASTM C 685.

• The concrete producer conducts calibration tests at least every 6 months.

• The equipment is calibrated for each new concrete mix before production. 628628628628628628

Ensure that batching plants have the following equipment and that the equipment meets the standards listed.

Ensure that bins and bin compartments meet the following standards:

• Adequate capacity for the required concrete production

• Supported on a rigid framework on a stable foundation capable of holding the bins securely

• Designed to discharge efficiently and freely into the weigh hopper

• Positive means of control that slows down and shuts off the material flow when the weigh hopper has the

correct quantity.

• Discharging mechanisms that prevent material leaks when closed

• Leak-free aggregate storage bins

• Divided aggregate storage bins for fine aggregate and each size of coarse aggregate

• Partitioned aggregate storage bin compartment that prevents the materials from mixing

• Leak-proof, moisture-proof cement bins with a vibrator or other mechanism to discharge cement

Ensure that weigh hoppers meet the following standards:

• Have suitable containers freely suspended from scales

• Have adequate capacity to maintain the Subsection 500.3.05.P, Table 5—Minimum Placement Rates

• Have a discharge mechanism that prevents material leaks when closed

• Have vents to permit air to escape

• Have vibrators or other equipment that ensures complete and efficient discharge of materials

• Have a dust seal and a port or valve for sampling cement

Scales used for weighing concrete materials shall have accuracy within plus or minus one percent under

operating conditions.

Ensure the following:

• When directed by the Engineer, the owner demonstrates the accuracy of the scales.

• Scales are kept clean and in good operating condition.

• The scale operator can clearly see indicating devices.

• The scale operator can easily access controls. 629629629629629629

Ensure that mixers and agitators meet the following requirements:

Provide mixers and agitators that meet these requirements:

Ensure that the mixer or agitator has a legible metal plate or plates attached in an easily visible location.

The plates shall indicate the rated capacity in cubic yards (meters) for mixing and agitating.

The mixer shall produce concrete that meets the requirements in the Table 1—Concrete Mix Table.

The mixer or agitator may be required to pass a mixer performance test. Mixer performance will be

evaluated at the discretion of the Engineer.

Mixer performance tests will include the following by the OMAT:

1) Taking samples of concrete at the one-quarter and three-quarter points of the batch discharge

2) Measuring the slumps of each concrete sample

If the two slump values differ by more than 2 in. (50 mm), do not use the mixer or agitator until it

meets the requirements of the test.

The Engineer may permit the equipment to be used if the 2 in. (50 mm) tolerance can be met by

using a longer mixing time or a smaller batch.

Follow these guidelines for mixing speed:

• Do not exceed 150 revolutions at mixing speed.

• Discharge all concrete from truck mixers before drum or blades reach 300 revolutions, including

revolutions at agitating speed.

• Use the mixing speed defined by the manufacturer for the mixing equipment.

• If the manufacturer’s definition of mixing speed is not available, use a mixing speed of 6 to 18 revolutions

per minute.

Maintain mixers and agitators as follows:

next batch.

remove them immediately at no expense to the Department. 630630630630630630

Use stationary mixers or truck mixers.

Ensure that stationary mixers meet the following standards:

1) Combine the concrete ingredients into a homogeneous, uniform mass within the specified time

and when loaded to capacity.

2) Efficiently and uniformly discharge the concrete within the tolerances allowed in

Subsection 500.3.02.D.1.c, Mixer Performance Test.

3) Permit discharge only after the specified mixing time has elapsed using a locking device.

Ensure that truck mixers meet the following standards:

• Meets the requirements listed in Subsection 500.3.02.D.4.a, Stationary Mixers

• Has an approved revolution counting device in good operating condition

• Does not haul more than the rated capacity in cubic yards (meters) as shown on the attached

capacity plates

Use truck agitators or truck mixers operating at agitating speed.

Ensure that agitators meet the following requirements:

Subsection 500.3.02.D.1.c, Mixer Performance Test

Keep concrete buckets clean and in good working condition.

Keep concrete buggies clean and in good working condition.

Concrete pumping equipment is subject to the Engineer’s approval. Use pumping equipment that has adequate

capacity and is suitable for the proposed work.

Do not use chutes longer than 50 ft. (15 m) without the Engineer’s permission.

Flush chutes and troughs with water after each run. Do not discharge this water into freshly placed concrete or

into conveyance unit.

Promptly remove hardened concrete from chutes and troughs.

Ensure that chutes and troughs meet the following requirements:

steep slopes

Use pipes or tubes to place concrete when the operation requires dropping the concrete more than 5 ft. (1.5 m).

Thoroughly clean the pipes or tubes after each pour.

Use pipes made of metal or other approved material and long enough to deposit the concrete as close to its final

position as possible. 631631631631631631

Provide enough vibratory units, including at least one additional stand-by unit in good working condition, to

compact concrete immediately after it is placed. Have a stand-by unit at the site before each pour is started.

On Projects consisting entirely of small pours (10 yd³ [8 m³] or less), the Engineer may waive the

stand-by requirement.

Ensure that vibrators meet the following conditions:

• Approved internal rotation-type design

• A power supply that constantly vibrates the concrete at frequencies of not less than 4500 impulses per minute

• A vibration intensity that visibly affects a mass of concrete with a 1 in. (25 mm) slump through at least a 18 in.

(460 mm) radius

Do not use vibratory screeds (screeds that use a transverse strike-off motion) without the Engineer’s approval.

Use screeds that are:

• Mechanically operated

• Designed and constructed to screed with the strike-off parallel to the center line

• Readily adjustable

• Capable of maintaining proper adjustment throughout the screeding operation

The two screed types are:

Unless otherwise noted on the Plans, use longitudinal screeds only on pour lengths of 70 ft. (20 m) or less.

Use transverse screeds on any pour, unless otherwise noted on the Plans. However, transverse screeds are

required on pour lengths above 70 ft. (20 m).

Support screeds outside the pour area that will receive a surface finish. Do not use intermediate supports

or guides.

Adjust screeds to the camber specified on the Plans. Check the camber as often as necessary.

Have the Engineer approve the following for screeds and their supports:

• Weight

• Durability

• Adjustability

• Accuracy

• Mechanical condition

• Operational results

Furnish the equipment necessary to check screed clearances and tolerances before pouring decks. 632632632632632632

Place concrete under water using the following underwater placement equipment:

Use a tremie when depositing concrete in water above 10 ft. (3 m) deep. Ensure that tremie is:

• At least 8 in. in (200 mm) diameter

• Constructed in sections with watertight couplings

Where the Engineer permits, use a bottom dump bucket in water up to 10 ft. (3 m) deep.

Ensure that the bottom of the bucket opens only when it touches the surface that receives the charge and that

the top of the bucket has a lid or cover.

To supply additional moisture to the concrete, use fogging equipment with the following characteristics:

• A heavy-duty pump capable of delivering 2-gal (7.6 L) of water per minute to a 0.062 in. (1.6 mm) diameter tip

at an air pressure of 100 psi (700 kPa).

An example of a suitable pump is the Alemite Pump 7878-A.

• The ability to consume approximately 22 ft³/min. (0.6 m³/min) of compressed air

• A 3/8 in. (10 mm) inside diameter hose long enough to reach all areas of the deck

• An adjustable spray gun and tip to provide various patterns of atomized spray or fog for changing

finishing conditions

An example of a suitable spray gun is the Gun Jet No. 43 with a 120-2 Multi Jet Nozzle.

If necessary, substitute other equipment that is capable of equal performance.

500.3.03 Preparation

Before beginning deck placement operations on each Project, and for individual deck pours of an unusual nature,

the Engineer will schedule a pre-pour conference with Project supervisory personnel, and a representative of the

concrete supplier, if applicable. Project supervisory personnel will coordinate with a representative from the

Concrete Branch of OMAT.

Conference topics of discussion include the following:

• Reinforcing steel support method

• Final screed setting check

• Anticipated placement rate

• Personnel number

• Equipment type

• Curing methods

• Adverse weather placement procedures

• Emergency procedures

• Other Work-related details 633633633633633633

500.3.04 Fabrication

Measure materials as follows:

allows bag cement, proportion the batch to use only whole bags.

proper corrections for aggregate surface moisture.

required amount.

Control batching as follows:

Do not use prestressed concrete deck panels unless approved by the Engineer.

Additives are required when specified herein or as directed by the Engineer.

footings.

material conditions dictate.

When using air-entraining additives as an option to improve workability or when required, do not exceed

the upper limit of the entrained air content requirement in the Table 1—Concrete Mix Table.

Use concrete-retarding additives in bridge concrete when the average temperature is above 65 °F (18 °C) (the

average of the expected high and the predicted low).

other appurtenances constructed separately from the decks.

within one hour after batching.

The Contractor may use water-reducing admixtures in Class AA concrete for bridge decks when conditions

do not require a retarder. The Contractor may use water-reducing admixtures in other concrete when job or

material conditions dictate a reduction in water requirements or when minimal set retardation is desired.

The laboratory may allow Type F water-reducing admixtures when the Contractor requests it. The Contractor

may construct bridge sections containing duct enclosures for stressing tendons with concrete using Type F

(AASHTO M 194/ M 194M) water reducer as approved by the laboratory. 634634634634634634

The Contractor may use fly ash as an additive in concrete to promote workability and plasticity. The

Contractor may use fly ash as a partial replacement for Portland cement in concrete if the following limits

are met:

of cement.

Portland Pozzolan Cement and Subsection 831.2.03.A, Fly Ash.

If high-early strengths are unnecessary, the Contractor may use granulated iron blast-furnace slag as a partial

replacement for Portland cement in concrete if the following limits are met:

Portland Blast-Furnace Cement and Subsection 831.2.03.A.3, Granulated Iron Blast-Furnace Slag

granulated iron-blast furnace slag.

Mix central-mixed concrete as follows:

The Engineer will determine the mixing time for central mixed concrete, but the minimum mixing time will

be one minute for stationary mixers of up to 1 yd³ (1 m³) capacity. Mixing time may be adjusted in the

following situations:

• The Engineer will increase the minimum time by 15 seconds for each additional cubic yard

• For mixers with a capacity above 3 yd³ (2 m³), the minimum mixing time may be 90 seconds if the

resulting mixture is homogeneous and meets the requirements of Subsection 500.3.02.D.1.c,

Mixer Performance Test.

• The Engineer may waive mixing time requirements for stationary mixers of improved types or new

designs that produce homogeneous concrete in less time than that established for a particular

capacity by the foregoing. For these types of mixers, the Engineer may establish a minimum

mixing time of one minute.

mixer by the end of the first 1/4 of the specified mixing time. 635635635635635635

Mix shrink-mixed concrete as follows:

the final mixing in truck mixers.

when adding water according to Subsection 500.3.05.M, Add Water to Concrete.

Mix transit-mixed concrete as follows:

concrete plant except the quantity of water that may be withheld according to Subsection

500.3.05.M, Add Water to Concrete.

speed within 30 minutes after loading the truck mixer.

For revolutions above those specified for mixing speed, use agitating speed.

until color additives are uniformly dispersed throughout mixture and disintegrating bags, if used,

have disintegrated.

until discharge.

Use Type I or Type II Portland cement or Type IP Portland-Pozzolan cement for bridge construction, unless

otherwise specified.

NOTES:

where the concrete containing the additive will contact the reinforcing steel.

Concrete Types: Use the tabulated results from the Table 1—Concrete Mix Table for the classes and specific

requirements for each class of concrete. Use the appropriate class of concrete shown in the Plans or

specifications for each component of a structure, of the type as follows:

If approved by the Engineer, you may use this class as high early-strength concrete and may use Type III

cement in concrete used for this purpose.

The Engineer may also specify the rate of compressive strength development when this concrete is used

NOTE: The Department will not add compensation to the Contractor for Class AA1 concrete when it is used

at the request of the Contractor.

636636636636636636

NOTE: Do not air-entrain Class A concrete deposited in water (seal concrete). Ensure that the concrete has

10 percent additional cement and sufficient water to provide a 6- to 8-in. (150- to 200-mm) slump.

Concrete subbase may be composed of a mixture of Portland cement and graded aggregate or Portland

cement, aggregate, and sand.

Determine laboratory acceptance strength by at least 8 compressive test specimens prepared and cured

according to AASHTO R 39.

X = f ’c + 2.0s

Where:

f ‘c = required minimum compressive strength for each class of concrete from the Table 1—Concrete

Mix Table

s = average standard deviation of all 28-day specimens made in the field representing concrete of a given

class from all ready-mix plants

Use the standard deviations shown in Table 4:

Table 4—Standard Deviations for Calculating Acceptance Strength

Class of Concrete

Standard Deviation (s)

Psi (MPa)

B 370 (2.5)

A 650 (4.5)

AA 620 (4.3)

D 590 (4.0)

AA1 540 (3.7)

AAA 500 (3.4) 637637637637637637

500.3.05 Construction

General construction responsibilities include:

pour unit during daylight hours.

If necessary, place concrete at night when adequate lighting facilities exist, and the Engineer approves of the

operations and facilities.

such as wind and sun before curing materials are applied and protect freshly poured concrete from exposure

to excess moisture and freezing for a minimum of 24 hours when such weather conditions exist.

Accept responsibility for the design, construction, protection, and performance of falsework. Repair or remove

and replace (as the Engineer directs) concrete, other material, or portions of the structure that are damaged or

destroyed due to falsework failure.

Construct falsework for prestressed post-tensioned concrete structures according to the Contract

Special Provisions.

Construct falsework for structures other than post-tensioned box girders as follows:

Ensure that falsework structural components that have similar functions in an individual permanent span have

the same geometric properties and are made of the same materials.

When designing and centering formwork, treat concrete as a liquid, and use the following weights:

• 150 lbs./ft.³ (23.6 kN/m³) for vertical loading

• 85 lbs./ft.³ (13.4 kN/m³) for horizontal loading

• 75 lbs./ft.² (3.6 kN/m²) live load for deck placement operations

Use the following falsework design criteria:

• Design and construct falsework logically so the Bridge Design Office can analyze it using a commonly

accepted structural design theory.

• Avoid exceeding safe working values for material stresses.

• Provide support for the imposed loads, without settling or deforming and a way to compensate for

settlement, if it occurs.

Support falsework using one of these methods:

• Support on piling driven and removed as directed

• Found on a footing approved by the Engineer

Construct and set falsework to provide the finished structure the specified camber and finished grade.

Place “telltales” at locations directed by the Engineer to observe how much the falsework settles. 638638638638638638

Ensure that forms meet the following design criteria:

• Provide wet concrete and other loads and forces of construction support without bulging between the

supports or bracing and without deviating from the lines and contours shown on the plans.

• Meet the design criteria for falsework in Subsection 500.3.05.B.1, Meet Design Criteria.

• Account for the use of retarded concrete.

Ensure that bracing, ties, and supports are placed accurately.

If the formwork appears to be inadequately supported, tied, or braced (before or during concrete placement), the

Engineer may require that the Work stop until the defects are corrected.

Except as noted, fabricate forms from the following materials:

• Lumber

• Plywood

• Metal

• Plastic

• Combinations of these

Use material free of defects that materially affect form strength or materially impair the accuracy or appearance of

the concrete surface.

Use the form materials as follows:

Construct wood forms as follows:

(50 mm) thick.

form liner.

Construct plywood forms as follows:

place of 1 in. (25 mm) thick lumber to construct forms, if necessary.

639639639639639639

produce satisfactory results.

comparable wooden forms.

Use tempered fiberboard for form liners when necessary if it is at least 1/4 in. (6 mm) thick. Use tempered

fiberboard 1/8 in. (3 mm) thick only to form open joints. Support the fiberboard with suitable spacers

arranged properly.

Use approved synthetic materials for forming open joints and for other special uses, if necessary.

Construct form supports using metal ties, anchors, and hangers as follows:

a depth of at least 1 in. (25 mm) without damaging the concrete.

are in compression.

the concrete.

metal tie fittings.

Construct temporary forms as follows:

will remain in place.

grades shown on the plans.

curves. Construct headwall forms as follows:

ragged edges remain.

The Contractor may choose, as an alternate to the above method, to build a circular form that exactly fits the

pipe circumference and face of the headwall form.

chamfers unless otherwise shown on the plans.

faces of the exterior beams. 640640640640640640

while placing concrete.

other bond breaker to keep concrete from sticking to the forms.

Inspection and approval does not diminish the responsibility to produce concrete surfaces free of warping,

bulging, or other defects.

directed by the Engineer:

• Repair the defects using approved methods.

• Remove and replace the affected portion of the work.

Reuse forms and form material in good condition and satisfactory as determined by the Engineer. Do not use

forms or form materials that are warped, cracked, split, bulging, have separated plies, or have unsatisfactory

form liner.

Ensure that used forms are mortar tight and produce a finished concrete equivalent to that produced by

new forms.

Unless otherwise designated on the Plans, construct and use permanent steel bridge deck forms for concrete

bridge deck slabs according to these Specifications. Do not use permanent steel bridge deck forms in panels

where longitudinal deck construction joints are located between stringers.

Provide a structurally satisfactory slab when using permanent steel bridge deck forms.

Designation SS, Grade 80/550, Coating Designation G-165/Z-500 and ASTM A 924/924M.

• Form

• Reinforcement steel

• Plastic concrete

yield strength for the material furnished. However, do not allow the unit working stress to exceed

36,000 psi (250 MPa).

as follows:

1) If deflection exceeds 1/180 of the design span or 1/2 in. (13 mm), whichever is less, use

intermediate supports.

2) Do not base deflection on a total load of less than 120 lbs./ft² (5.7 kN/m²).

parallel to the form flutes. 641641641641641641

of the American Iron and Steel Institute Specification for the Design of Cold Formed Steel

Structural Members.

Figure 1. (Figure 1 metric).

FIGURE 1

concrete deck.

supporting structural members.

steel grades.

Have welders certified by the Department weld metal deck forms or supports for metal deck forms.

Install and maintain forms in a mortar-tight condition and according to approved fabrication and erection Plans.

Place transverse construction joints at the bottom of a flute. Field drill 1/4 in. (6mm) weep holes no less than 12 in.

(300 mm) on center along the line of the joint.

Install highway bridge forms with a 1 in. (25 mm) minimum clearance between the top of the form and the

bottom of the main deck reinforcement. See Figure 1.

Install railroad bridge forms as follows:

slab specified by the plans.

Engineer approves, use fastener pins driven into place by a power tool.

tensile stresses.

welds are permitted. 642642642642642642

Repair permanently exposed form metal to the Engineer’s satisfaction if the galvanized coating is damaged.

Type II and has no color added.

Provide runways into a deck pour area for moving buggies. If the Engineer approves, use runways to bridge a

previous pour that has not reached the minimum strength or age requirements in Subsection 500.3.05.AF.4, Live

Loads—Pouring Equipment.

Construct and support runways to protect the forms and the reinforcement steel position.

Provide a work bridge on deck pours. Support the bridge outside the area of the pour receiving a surface finish. If

two or more spans will be poured on the same day, the Engineer may require two work bridges.

Design and construct work bridges to meet the following:

• Do not allow the bridge to sag into the fresh concrete.

• Construct the bridge so that transverse finish and curing material can be applied easily regardless of the

screed type.

Add water to the concrete at the concrete plant. Do not add indiscriminate amounts of water at the job site.

If placement conditions require concrete of a more workable consistency, add small amounts of water at the job

site if approved by the Engineer.

Add water at the job site as follows:

The Engineer will not approve additions of water that cause the total amount of water to exceed the maximum

water/cement ratio established in the Table 1—Concrete Mix Table .

The Engineer will reject concrete with water added to it that produces a higher slump than specified in the

Table 1—Concrete Mix Table .

exceeded mixing or haul time limitations.

Concrete ingredients may be proportioned volumetrically when non-air entrained concrete is used in

miscellaneous concrete, non-exposed footings, culverts smaller than bridge culvert size, or when approved

by the Engineer. 643643643643643643

Prepare for concrete placement as follows:

Subsection 500.3.05.P, Table 5—Minimum Placement Rates for Bridges, Culverts and Retaining Walls.

panel before placing the slab concrete.

with water.

Acceptance tolerances for each class of concrete are listed in the Table 1—Concrete Mix Table .

Conduct the applicable tests according to the procedures in the Sampling, Testing, and

Inspection information.

If concrete is not produced, placed, and finished according to the minimum placement rates, the Engineer may

reject the pour. Concrete pours of a similar nature and size will not be allowed until the problem is corrected and

the placement rate met.

The minimum placement rates are listed in Table 5:

TABLE 5—MINIMUM PLACEMENT RATES FOR BRIDGES, CULVERTS AND RETAINING WALLS

Pour Size in Cubic Yards (Meters) Minimum Placement Rate in Cubic Yards (Meters) per Hour

0-25 (0-19) 10 (8)

26-50 (20-39) 15 (12)

51-75 (40-59) 20 (15)

76-100 (60-75) 25 (20)

101 and over (76 and over) 30 (25)or as designated on the Plans or in the Special Provisions

The minimum placement rate for columns shall be the same as for culvert sidewalls and wingwalls.

Pour handrail, parapet, curb, and barriers at a rate satisfactory to the Engineer.

Pour Size in Cubic Yards (Meters) Minimum Placement Rate in Cubic Yards (Meters)per Hour

0–25 (0-19) 15 (12)

26–50 (20–39) 20 (15)

51–75 (40–59) 25 (20)

76 and over (60 and over) 30 (25) or as designated on the Plans or in the Special Provisions 644644644644644644

Structure Minimum Placement Rate in Cubic Yards (Meters)per Hour

Footings and slabs Same as for bridge substructures

Sidewalls and wingwalls Use placement rates so that fresh concrete is not placed on

concrete that has attained its initial set.

Cover all concrete with fresh concrete within 45 minutes.

Structure Minimum Placement Rate in Cubic Yards (Meters)per Hour

Footings Same as for bridge substructures

Walls Same as for culvert sidewalls and wingwalls

Place concrete as follows:

time limitations in Subsection 500.2.01.E.1, Haul Time Limitations.

inferior concrete.

continuous stream without air pockets.

NOTE: Convey and place concrete by pumping only when specified in the Contract or when authorized by

the Engineer.

the concrete.

Do not allow concrete to free-fall more than 5 ft. (1.5 m) from the pipe or tube.

the concrete in adjoining areas if the Engineer requires. Removal prevents cold joints and displaced or

damaged reinforcement.

645645645645645645

corners of forms.

the forms.

Engineer approves alternate methods.

particles are submerged in the concrete mortar.

locations difficult to reach with vibrators.

Place construction joints according to the Plans or as directed by the Engineer.

If an emergency affects continuous placement, the Engineer will decide if a construction joint is allowed. If

allowed, the Engineer will provide instructions about where and how to make the joint.

The Engineer may eliminate certain construction joints if placement, finishing and forming methods can produce

satisfactory results.

Create construction joints as follows:

initial set.

delay cleaning until the concrete is thoroughly hardened.

bonded, loose, or foreign material.

Ensure that laitance is completely removed from the following:

• Joints between decks and curbs

• Tops of seal courses

• Construction joints in concrete exposed to sea water

Do not drive pile, blast, or perform other operations that vibrate the formwork or the concrete noticeably before

the concrete reaches a strength of 2,000 psi (15 MPa) and is 3 days old.

Protect fresh concrete from rainfall with waterproof material such as tarpaulins or plastic film. Ensure that the

waterproof material is ready before pouring and is sufficient to cover the area of the pour. 646646646646646646

Do not use calcium chloride or any other admixture containing chloride salts in concrete placed on permanent

steel bridge deck forms.

Ensure that the tolerances are accurate for bar reinforcement placement in cast-in-place concrete so the top

clearance to the bar reinforcement complies with Subsection 511.3.05.G.6, Bridge Deck Slab Tolerances.

Place bridge deck concrete according to the Contract Specifications and as follows:

cross-section.

unit), pour and finish the concrete in the numbered sequence shown on the plans, beginning with the

lowest number.

number in any sequence.

curb, parapet, and handrail pours.

pouring the deck slab.

pouring decks.

the first four stems are placed. After the first four stems, avoid getting more than three stems ahead

of the advancing line of the deck pour and lagging by more than the space between stems.

T-Beam spans supported without intermediate false bents. However, ensure that the slab is placed

before a cold joint develops between the stem and slab.

This requirement may be waived under certain conditions if the succeeding pour can be completed (except for

final finishing) within four hours of the initial placement of the day. The Engineer must give written approval for

this requirement to be waived.

Unless otherwise shown on the plans, do not place handrail, sidewalks, parapets, and curbs in a complete

unit until all the deck slabs in the unit have been poured.

• Forward with or slightly ahead of the concrete

• Along the bottoms and sides of the forms

• Around the reinforcement steel 647647647647647647

following locations:

• Construction joints

• Expansion joints

• Valleys and ends of form sheets Screed the concrete as follows:

surface screeded to the required grade.

Perform further screeding with minimum disturbance to the surface already brought to the grade.

located where the slab joins the curb, parapet, or sidewalk.

• Longitudinal Screed

Before doing the final screeding, place enough concrete in front of the screeding position to

deflect the dead load.

• Transverse Screed

On beam or girder-supported spans with skew angles of 65° or less, place and operate the truss

or beam supporting the strike-off parallel to the skew and make the advancing pour line parallel

to the skew.

On beam or girder-supported spans with skew angles between 65° and 90°, position the screed

either on the skew or at right angles to the bridge center line.

On superstructures supported by non-deflecting falsework and on beam- or girder-supported

spans with a total dead load deflection no more than 1/2 in. (13 mm), position the screed at right

angles to the bridge center line and make the advancing line of pour at right angles to the bridge

center line.

excess grout from the leading edge of the screed at these construction joints.

rounded edge.

approximate the plan radius either by hand or by mechanically operated grinding stones.

648648648648648648

concrete a final finish by belting, brooming, or dragging.

• Belt longitudinally using a wet canvas belt. Limit belting to spans no longer than 40 ft. (12 m).

• Drag transversely or longitudinally with a wet burlap drag.

• Broom transversely using a stiff-bristled broom.

• Gutter lines

• Joints

• Drains

approach slabs perpendicular to the center line as follows:

1) Do not begin grooving until the bridge deck is cured according to Subsection 500.3.05.Z, Cure

Concrete.

2) If necessary, groove in conjunction with planing required to make the surface corrections

specified in Subsection 500.3.06.D, Bridge Deck Surface Check. Wait until the concrete is hard

enough to support the equipment without distorting.

3) Cut grooves into the hardened concrete using a mechanical saw device capable of producing

grooves 0.125 in. (3 mm) wide, 0.125 in. (3 mm) deep, and 0.50 in. (13 mm) apart,

center-to-center.

4) Extend the grooves across the slab to within 1ft. (300 mm) of the gutter lines.

5) Do not groove within 3 in. (75 mm) of bridge joints, including “dummy” joints detailed in

the plans.

Place concrete barrier or parapets on bridge decks. The slip form method with an approved self-propelled

extrusion machine as specified in Section 621 is optional.

Deposit concrete in water only when required by the Plans or when considered necessary by the Engineer.

When depositing the seal concrete, follow these guidelines:

• Keep the water as motionless as possible.

• Place the concrete continuously from beginning to end.

• Ensure that the concrete surface remains as horizontal as possible.

Place seal concrete as follows:

bottom dump bucket, or other approved means.

1) Support tremies so that the discharge end can move freely over the entire top surface of

the work.

2) Support tremies so that they can lower rapidly to stop or retard the flow of concrete.

3) At the beginning of the work, close the discharge end to keep water out of the tube.

4) Keep the tube sealed.

5) Keep the tremie tube full to the bottom of the hopper.

6) When dumping a batch into the hopper, induce concrete flow by slightly raising the discharge

end and keeping it within the previously deposited concrete. This maintains a seal and forces the

concrete to flow into position by hydraulic head. 649649649649649649

1) Ensure that the bottom-dump bucket is level full.

2) Open the bucket only when it rests on the surface that will receive the charge.

3) In lowering and raising the bucket, do not move the water unnecessarily.

longer waiting period is necessary.

211.3.05.C, Boring of Foundations and Seals.

may decide to core the seal to determine acceptability.

density and create construction joints and prepare their surfaces according to the requirements of Subsection

500.3.05.R, Create Construction Joints.

Pour CS concrete as follows:

• Ensure that the minimum depth is the same as shown on the plans.

• Do not vary the depth variation more than 1 in. (25 mm).

• Ensure that the surface finish is generally smooth and uniform.

• Smooth or fill float marks, voids, and other deformities exceeding 1/2 in. (13 mm) before placing

approach slabs.

placing the slabs.

6 in. (150 mm).

Repair or replace sheeting deemed unsatisfactory as directed by the Engineer.

When pouring concrete in cold weather, keep the concrete temperature at the point of delivery at least 50 °F

(10 °C). Do not use accelerator-containing chlorides.

Mix and pour concrete in cold weather as follows:

• Do not use materials in concrete mix that contain frozen lumps.

• Do not incorporate water and aggregates into the mix with temperatures more than 150 °F (65 °C).

• If aggregates or water temperatures are above 100 °F (40 °C), discharge the aggregates and water into

the mixer and allow the temperatures to equalize before adding the cement.

• Heat aggregate with steam, hot water coils, or other methods that do not damage the aggregates. Do not

heat aggregates with direct flame. 650650650650650650

• Keep concrete above 50 °F (10 °C) for at least 72 hours after placement.

• Protect concrete from freezing for 6 days after placement.

Reduce hazards and difficulties related to placing and finishing concrete in hot weather before pouring. The

Engineer may require measures to prevent concrete workability reduction, losses from cement hydration,

evaporation, drying, or elevated concrete temperatures.

Cool forms and reinforcement with water immediately before placing concrete. Meet the minimum placement

rates specified in Subsection 500.3.05.P, Table 5—Minimum Placement Rates for Bridges, Culverts, and

Retaining Walls.

Keep concrete cool as follows:

of discharge from the delivery unit.

placement when the air temperature cools if the Engineer requires.

using ice, ensure that the ice melts before the batch is discharged from the mixing unit.

Do not “splash on” water to aid screeding or finishing operations.

For bridge decks, fog the surface when required, according to Subsection 500.3.05.Z.3, Bridge Deck Curing.

If needed, use wind screens to prevent thermal or shrinkage cracks caused by rapid concrete surface drying.

Concrete curing is an integral part of the concrete placement operation. Improperly cured concrete will be

considered defective.

If the Engineer determines that curing procedures do not comply with these Specifications, stop placing concrete.

Resume concrete placement after taking remedial measures to ensure proper curing.

Begin curing unformed surfaces when the water sheen disappears from the surface or immediately after applying

the surface finish. Continue curing for 5 days.

Cure the formed surfaces after removing the forms. Remove them within 5 days after placing concrete. Continue

curing until the concrete is 5 days old (from the time it is poured).

Cure concrete surfaces exposed to air using methods that prevent premature drying or moisture loss. Ensure that

curing conditions are the same throughout separate curing areas.

Use either or a combination of the two methods specified for curing concrete except bridge decks. Cure bridge

decks as described in Subsection 500.3.05.Z.3, Bridge Deck Curing.

Cure colored concrete in accordance with manufacturer’s instructions.

Do not use a method that causes the concrete to be alternately wet and dry.

Cure concrete properly by supplying additional moisture through ponding, sprinkling, or fogging and then

retaining the moisture as follows:

Cover with at least 2 in. (50 mm) of sand. Cover with at least 3 in. (75 mm) of hay or straw.

651651651651651651

Keep concrete moist before and during the rubbing from the Type III—Rubbed Finish.

Start curing immediately after the rub using approved waterproof paper, plastic sheets, or membrane-forming

curing compounds, except when curing compounds are prohibited.

Ensure that the sheets and paper meet the requirements of AASHTO C 171 and use them as

follows:

• Use the widest possible widths.

• Lap adjacent sheets at least 6 in. (150 mm).

• Seal the laps with tape, mastic, glue, or other approved methods to form a waterproof cover of

the entire area.

• Keep the curing material from being displaced by wind.

• Immediately replace or repair sheets or paper that tear, break, or become damaged during the

curing period.

Membrane-Forming Curing Compounds

Use as the curing agent AASHTO C 309, membrane-forming curing compounds, Type 1-D, Class A or B,

or Type 2, Class A or B, white pigmented. Use the curing agent as follows:

• Do not use membrane-forming curing compounds on bridge decks or prestressed concrete

bridge members, or in construction joint areas.

• When the water sheen disappears from the concrete surface, apply the curing compound

uniformly to unformed areas.

• Apply the compound to formed surfaces if the forms are removed during the 5-day curing period.

• Cure the areas to be rubbed with liquid membrane-forming compounds for curing concrete,

Type1-D, Class A or B (non-acrylic).

• Apply curing compound with fine-spraying equipment.

• Thoroughly agitate the compounds just before using them.

• Spray the surface again immediately after the first application at right angles to the

first application.

Apply at least 1 gal (1 L) for each 150 ft.² (3.7 m²) of surface.

• Do not apply curing compound to the following:

• Joints where a concrete bond is required

• Reinforcement steel

• Joints where joint sealer will be placed

• Close the surface to pedestrian or vehicular traffic for 7 days unless the surface is protected by

planks, plywood, or a layer of sand at least 1 in. (25 mm) thick.

Do not place this protection until at least 12 hours after applying the curing compound. 652652652652652652

b.

Cure bridge deck concrete as follows:

keep a film of water on the surface.

side up.

For the bottom layer, use a polyethylene film. For the top layer, use a white, burlap polyethylene sheet

or a white, co-polymer-coated, absorbent, non-woven synthetic fabric.

and moisture retention and has no holes or tears.

additional moisture.

The surface of parapets, sidewalk, end post, and horizontal and vertical faces of curbs are not considered part

of the bridge deck. Cure these structures using the general curing methods in Subsections 500.3.05.Z.1,

General Curing—Supplying Additional Moisture, and 500.3.05.Z.2, General Curing—Preventing Moisture Loss,

unless the surfaces will receive a special surface coating (Subsection 500.3.05.AB.4, Type III—Special Surface

Coating Finish).

Do not cure surfaces receiving a special surface coating with membrane-forming curing compounds.

Do not cure surfaces receiving protection surface treatment (75 percent boiled linseed oil and 25 percent

mineral spirits solution) with membrane-forming curing compounds that contain acrylics.

AA. Prevent Plastic Shrinkage Cracking

Take precautions to prevent plastic shrinkage cracking of concrete by doing the following:

• Provide wind screens

• Provide fogging equipment

• Apply temporary wet coverings before moisture loss begins

The Engineer will evaluate the effects of plastic shrinkage cracks and will require repair of cracks that create

structural defects and corrode reinforcement steel. 653653653653653653

AB. Finish Concrete

Concrete surface finishes are classified according to whether the surfaces are formed or unformed.

Refer to Table 6.

When other Sections of the Specifications for concrete work state that the requirements of Section 500 apply,

finish the concrete according to the other sections.

TABLE 6—CONCRETE FINISH TYPES

Surface Finish Type

Formed Type I—Ordinary Formed Surface Finish

Type II—Special Formed Surface Finish

Type III—Rubbed Finish

Type III—Special Surface Coating Finish

Unformed Type IV–Floated Surface Finish

Type V–Sidewalk Finish

Type VI–Stair Tread Finish

Except for bridge deck finishes, which are covered in Subsection 500.3.05.T, Place Bridge Deck Concrete, step 9,

finish all structural concrete surfaces with one or more of the finishes described here, unless otherwise shown on

the plans.

Complete formed concrete surfaces with this finish. However, leave concrete exposed directly to sea water

undisturbed unless the Engineer requires additional work. See Subsection 500.3.05.V, Place Seal Concrete,

step 6.

Achieve a Type I finish as follows:

• Cavities produced by forms or ties

• Holes

• Broken corners or edges

• Defects

• Honeycombed edges

cement in the same ratio as in the concrete.

Use epoxy mortars in areas where heat generation and moisture will not decrease patch performance.

General Curing—Supplying Additional Moisture and 500.3.05.Z.2, General Curing—Preventing

Moisture Loss.

considers it necessary to achieve a uniform and pleasing appearance. 654654654654654654

Give a Type II finish to the following:

• Exposed portions of pipe headwalls and culverts

• Parapets and wingwalls

• Ends of culvert slabs and walls

Achieve a Type II finish as follows:

Type I finish and blending all pointed and patched areas.

considers it necessary to achieve a uniform and pleasing appearance.

Apply a Type III finish to bridge areas checked in the table of Bridge areas Requiring a Type III Finish, below

and to exposed areas of retaining walls, unless the Plans specify otherwise.

Achieve a rubbed finish as follows:

all patches are thoroughly set, but before applying the required curing compound.

If finishing is postponed or there is not enough labor to keep it up-to-date, the Engineer will order a

stop to any other work until the finishing is satisfactory.

either the second or the final rubbing.

carborundum stone or equal abrasive until a paste comes to the surface.

Keep the entire concrete surface moist during rubbing to assure adequate curing.

with no pits or irregularities.

abrasive, leaving a smoothly textured surface that is uniform in color.

by spreading it on the surface to be rubbed.

concrete placement or rubbing. 655655655655655655

Bridge Areas Requiring a Type III Finish (X)

Single

Bridge

Over

Stream

Multiple

Bridges

Over

Stream

Single

Bridge

Over

Railroad

Multiple

Bridges

over

Railroad

Single

Bridge

over

Traffic

Artery

Multiple

Bridges

Over

Traffic

Artery

Railroad

Bridge

Over

Traffic

Artery

Pedestrian

Bridge

Over

Traffic

Artery

All exposed substructure areas,

except tops and bottoms of caps. (5)

X X X X

Outside surface of any exterior

concrete beam, Lt. or Rt. (1), (2)

X X

Outside surface of any exterior

concrete beam, LT. and Rt. (1), (3)

X X X X

Vertical surfaces of overhangs, curb,

or sidewalk

X X X X X X X X

All vertical surfaces outside exterior

beam, Lt. or Rt. (2)

X X

All vertical surfaces outside exterior

beam, Lt. and Rt. (3)

X X X X

End bent cap beyond outside beam

or girder

X X X X

End bent end walls beyond outside

beam or girder

X X X X X X X X

End bent posts and end bent

wingwalls all exposed surfaces

X X X X X X X X

Traffic face of curbs X X X X X X X

Entire handrails and posts, handrail

parapets, and barriers (4), (5)

X X X X X X X X

All other locations specified on

Special Provisions

X X X X X X X X

Notes:

For bridges using PSC Beams or PSC Deck Units, a Type III Special Surface Coating Finish shall be used where a Type

III finish is required for exterior beams. For bridges using PSC Beams or PSC Deck Units, a Type III Special Surface

Coating Finish shall be used where a Type III finish is required for exposed substructure areas. The Type III Special

Surface Coating Finish shall also be used on the exterior vertical faces of the parapet, barrier, and overhangs where

PSE Beams or PSC Deck Units are used. 656656656656656656

A Type III—Special Surface Coating Finish may be substituted for a Type III—Rubbed Finish.

The special surface coating finish consists of either a Class A or a Class B coating system, applied to produce

a masonry-like textured finish on concrete surfaces.

For contiguous structures, whether in the same Contract or in separate Contracts, use the same brand of

special surface coating.

If contiguous structures are in separate contracts, coordinate the Work with the other Contractor so that

coating is applied as near as possible to the same time.

If contractors cannot coordinate Work, the one who finishes the work last shall use the same brand or shall

recoat all contiguous areas to provide a uniform appearance.

Achieve a special surface coating finish as follows:

Select coating material from the QPL 17.

Have the coating manufacturer or the laboratory determine compatibility.

remove forms with bond-breaking agents or excessive oil.

• Class A coatings at a rate that develops a 1/16 in. (1.5 mm) thick coating.

• Apply Class B coatings at a maximum rate of 60 ft.² per gallon (1.5 m² per liter).

• Ensure that the temperatures of the air, concrete, and compound are above 50 °F (10 °C).

• Apply a test section as directed by the Engineer to determine the acceptance of a coating under

field conditions.

• Apply the coatings using a method that produces an acceptable finish, such as spraying, rolling,

or a combination of these.

and appearance.

barriers.

Use a Type IV finish only on the horizontal surfaces of the following:

• Curbs and sidewalks

• Tops of caps and footings

• Surface of slope paving

• Other similar structures

Apply the Type IV finish as follows:

wood float.

reduce the wearing quality of the surface.

657657657657657657

Apply a Type V finish as follows:

the Engineer.

between the curb corner and the longitudinal sidewalk groove.

Achieve a Type IV finish using a stiff-bristled broom.

AC. Remove Forms

Do not remove forms and their supports, including falsework, until the Engineer approves. Use a removal method

approved by the Engineer. Approval does not relieve responsibility for the safety of the Work.

Use a removal time shown on the Plans or specified by the Engineer.

Use Table 7 to help establish when forms can be removed safely. However, do not count days where the

temperature at any time during the day is at or below 40 °F (4 °C), unless the cold weather concrete protective

measures described in Subsection 500.1.03.G, Cold Weather Concrete Curing and Protection Plan were used.

TABLE 7—ESTIMATE OF FORM REMOVAL TIME

Form Time Required

Bottom of beams 10 days

Bottom of caps, trestle pile bents 4 days

Bottom of all other caps 7 days

Overhangs and slabs, including culverts 7 days

Columns and retaining walls 18 to 48 hours

Sides of beams, posts, rails, caps, footings, wingwalls, and parapets 12 to 24 hours

Bottoms of cast-in-place rails and diaphragms 48 hours

Front face of curbs 3 hours

If using high-early strength concrete, the Engineer may reduce the time limitations if the concrete develops

satisfactory strengths.

Remove forms and falsework without injuring the concrete surface or overstressing the concrete members.

Ensure that the stress from the weight of the removal process is transferred gradually and uniformly to the

concrete.

At the Contractor’s request, time of removal may be controlled by field tests on cylinders, subject to the

following conditions:

determined by the Engineer.

strength is achieved. 658658658658658658

AD. Apply Protective Surface Treatment

When the Plans specify a protective surface treatment, apply a boiled linseed oil mixture of 75 percent boiled

linseed oil and 25 percent mineral spirits by volume to the concrete surfaces.

Use linseed oil that meets the requirements of ASTM D 260, Type I or Type II. Use a quality commercial mineral

spirit that passes infrared spectroscopic analysis to the satisfaction of the laboratory.

Unless otherwise noted on the Plans or the manufacturer’s recommendations, apply the mixture as a preservative

seal coat to the top surfaces of bridge decks, curbs, and sidewalks and to the inside vertical faces of curbs,

parapets, and end posts. Protect metal handrailing and metal handrail posts from treatment.

Apply the protective surface treatment as follows:

CAUTION: Because the linseed oil-petroleum spirits mixture has a low flash point and is readily flammable,

protect the mixture from fire, especially cigarettes and sparks. Prohibit traffic from the treated area until the

Engineer determines the concrete has regained its dry appearance.

expansion joint sealing compound is placed.

is at least 50 °F (10 °C).

the structure.

If the structure meets the following exceptions, apply the treatment after using the structure for hauling.

• Temperature limitations prohibit application.

The Engineer will send a written notification to the Contractor (or Bridge Contractor) if temperature

requirements prohibit application.

• The structure is absolutely required for hauling to complete a Contract.

Request a written approval from the Engineer if hauling across a structure before the treatment is

placed.

allow the treatment to penetrate completely.

immediately upon request by the Engineer.

operations.

(8.5 m²).

plans, or manufacturer. 659659659659659659

AE. Apply Graffiti-Proof Coating

When the Plans specify a graffiti-proof coating, apply the coating system to concrete surfaces or over special

surface coatings. Use material that complies with Section 838.

Apply the coating as follows:

• Weather conditions

• Material preparation

• Coating application

• Number of coats

AF. Expose New Concrete to Loads

Prohibit dead or live loads during or after construction except as described in this section. If using high early

strength concrete, the Engineer may reduce time limitations if the concrete develops adequate strength.

After pouring footings, do not begin work on columns or piers for at least 12 hours.

After pouring columns, do not begin cap construction for at least 24 hours.

Do not place beams on caps or place falsework and forming for concrete T-Beam construction before the cap

concrete reaches a minimum strength of 2,500 psi (17 MPa).

If necessary, stockpile construction materials on decks within a complete unit (a simple span or continuous or

cantilever unit) if the following conditions exist:

• The deck concrete of the complete unit reaches its 28-day cylinder strength.

• The deck concrete is at least 10 days old.

• The curbs are at least 5 days old.

The Engineer must approve the location, height, and spread of the loads.

On composite-design bridges (those that have prestressed concrete beams or steel beams with shear

connectors), do not pour curbs, parapets, or sidewalks until the deck concrete reaches a minimum strength of

1,500 psi (10 MPa) or is at least 3 days old.

Do not backfill any section of a concrete box culvert until the last concrete placed in that section is at least

14 days old, unless early cylinder breaks indicate otherwise.

If early cylinder breaks indicate that design strength has been achieved, backfill sections of culverts when the

concrete placed last is at least 7 days old.

Do not allow power-operated concrete buggies to cross a deck until the concrete reaches a minimum

strength of 1,500 psi (10 MPa) or is at least 3 days old.

Allow hand-operated buggies to cross after the concrete is 24 hours old. 660660660660660660

Do not place mixers on a deck in a complete unit (a simple span or continuous or cantilever unit) until the

deck concrete of the complete unit reaches its 28-day cylinder strength and is at least 10 days old.

When deck concrete reaches its 28-day cylinder strength and is at least 10 days old, allow mixer trucks on the

unit during the curb concrete pour only if the pour is completed within 45 minutes of being started.

Do not allow any equipment on the unit for 5 days after curb pours.

The Engineer may allow concrete placement procedures that use heavy lifting equipment on the decks if the

following conditions exist:

• The deck concrete reaches its 28-day cylinder strength.

• The deck concrete is at least 14 days old.

• The curbs on the deck are at least 10 days old.

Use a new bridge for hauling only if no other practical haul routes are available and only if the Engineer

permits it.

requirements are violated, the Engineer will limit loads to the following:

• Single 32,000 lb. (14 515 kg) axle when the bridge design loading is HL-93 or HS 20-44 Single

24,000 lb. (10 886 kg) axle when the bridge design loading is HS 15-44 or H 15-44

TABLE 8—WEIGHT LIMITS FOR HAULING ON NEW BRIDGES

Axle Criteria

Bridge Design Loading

HL-93 or HS 20-44 Loading HS 15-44 or H 15-44

Maximum Axle Load Per Axle 60,000 lbs. (27 216 kg) 44,000 lbs. (19 958 kg)

Maximum Axle Load on Dual

Axles Per Axle

45,000 lbs. (20 412 kg) 33,000 lbs. (14 969 kg)

Maximum Total Load 100,000 lbs. (45 360 kg) 73,000 lbs. (33 113 kg)

and has a minimum compressive strength of 3,000 psi (20 MPa).

Protective Surface Treatment).

handrail, handrail posts, end posts, and curb faces before hauling begins.

following loads occur:

• Bridges designed for HL-93 or HS 20-44 Loading:

— Loads on single axles exceed 32,000 lbs. (14 515 kg)

— Loads on each dual axle exceed 24,000 lbs. (10 886 kg)

• Bridges designed for HS 15-44 or H 15-44 loading:

— Loads on single axles exceed 24,000 lbs. (10 886 kg)

— Loads on each dual axle exceed 16,000 lbs. (7257 kg)

When axle loads do not exceed these loads, ensure that vehicle speeds are 15 mph (24 kph) or less. 661661661661661661

Stabilize sandy and other unstable soils (at no expense to the Department) with crushed stone or

other suitable material for at least 10 ft. (3 m) from the end of the bridge or approach slab.

rest on either the paving rest of the bridge end or the pavement subgrade at the end of the approach

slab. Keep the strip in place for protection during incidental hauling. Remove it before constructing

the adjacent pavement.

Keep the top of each timber strip flush with the top of the concrete surface. Fit the strip tightly against

the end of the bridge or approach slab. If the timber strip is displaced, stop hauling until the strip is

reset or replaced.

AG. Complete Corrective Work

After the Department gives the deck surface a Ride Quality Test described in Subsection 500.3.06.E, Ride Quality

Test, complete corrective work at no cost to the Department and before doing the final surface texturing.

Complete corrective work as follows:

(13 mm).

quality meets the requirements of this Specification.

AH. Plane the Deck

The Contractor shall schedule the ride quality test at least 7 days before needed by contacting the Office of

Materials and Testing, Concrete Branch. Ensure that the area to be tested is clean and clear of obstructions.

When possible, delay expansion joint installation and temporarily bridge the joint to operate Lightweight Profiler

and planing equipment across the joint.

Planing responsibilities are shown in Table 9:

TABLE 9—PLANING RESPONSIBILITIES

Area Planed Person Responsible

Bridge decks Bridge Contractor

Approach slabs constructed under the bridge Contract Bridge Contractor

Approach slabs constructed under the roadway Contract Roadway Contractor 662662662662662662

AI. Perform Retaining Wall Incidentals

Retaining wall incidentals are as follows:

Unless otherwise shown on the Plans or in the Special Provisions, ensure that drainage for retaining walls is

either Alternate A or Alternate B on Georgia Standards 4941B and 4949 Series.

Ensure that the Number 10 concrete sand complies with Subsection 801.2.02, Fine Aggregate for Portland

cement Concrete of All Types and for Mortar and has a permeability coefficient of at least 100 ft. (30 m)

per day.

The Engineer may waive the grading requirement for Number 10 concrete sand if the permeability coefficient

of the material does not exceed 500 ft. (150 m) per day.

Omit the drainage blanket and stone for retaining walls only when the height does not exceed 6 ft. (1.8 m).

When the Plans specify different drainage details, furnish, place, or build the various items according to the

plan requirements.

When waterproofing and damp proofing are specified in the Plans, comply with the requirements of Sections

530 and 531.

AJ. Place Utility Installation Hardware

When the Plans require placing utility installation hardware, the utility company involved will furnish the items.

Place the items as directed on the plans or Shop Drawings. All other work, including painting as required, is the

utility company’s responsibility.

AK. Widen Bases and Pavement

When using narrow sections of Portland cement concrete to widen existing bases or bases and pavements, use

Class B concrete as shown on the Plans or as directed by the Engineer.

AL. Open the Structure to Traffic

Open a structure to traffic other than haul traffic after all concrete in the decks, parapets, or curbs (sidewalks)

reaches its 28-day cylinder strength and is at least 14 days old.

500.3.06 Quality Acceptance

When job site test specimens fail to meet the strength requirements in the Table 1—Concrete Mix Table ,

determine the Final Acceptance or rejection of concrete in place by coring or non-destructive testing.

At the Contractor’s request, the Department will determine the removal time for forms by conducting field tests

on cylinders.

Tests are subject to the following:

If there are honeycombed areas that extend beyond the reinforcement steel, the Engineer may reject the entire

pour with the honeycombed area. 663663663663663663

The Engineer will carefully observe the construction methods used during all phases of the bridge deck slab

construction. These phases include the following:

• Metal form installation

• Reinforcement location and fastening

• Concrete item composition

• Mixing procedures

• Concrete placement and vibration

• Bridge deck finishing

Provide the needed facilities for the Engineer to safely and conveniently inspect the concrete.

The concrete inspection procedure is as follows:

two areas of the deck for each slab pour. This test checks for concrete soundness and form bonding.

The two areas will encompass at least 10 percent of the total area of the deck pour.

procedures used call for an inspection of the underside of the deck, remove at least one section of the forms

for each span in the Contract.

evidence that the concrete mix and the placement procedures are acceptable.

procedures warrant additional inspection.

and supports neatly and securely.

other defects.

repair the concrete as the Engineer directs and give it an ordinary surface finish according to the Contract

Specifications.

and repair the slab.

If the construction methods used and the inspection results indicate that the slabs have sound concrete, the

Engineer may moderate the amount of random sounding and form removal after a substantial amount of slab

has been constructed and inspected.

After the final strike-off of the concrete and as close behind the final strike-off as possible, the Engineer will check

the surface with a 10 ft. (3 m) straightedge.

Attach the straightedge to a broom-type handle for easy control and use.

Bridges and approach slabs must meet a 1/8 in. in 10 ft. (3 mm in 3 m) straightedge check made longitudinally

and transversely. 664664664664664664

After the bridge decks and approach slabs are completed, the Contractor will contact the Department’s Office of

Materials and Testing, Concrete Branch to schedule to have a Ride Quality Test performed using the Lightweight

Profiler and a profile index value determined according to GDT 134.

The Department will conduct the test as follows:

Subsection 500.3.06.D, Bridge Deck Surface Check.

for each lane.

The average value must not exceed 15 in./mile (235 mm/km) for each lane.

After the test is complete, correct individual bumps or depressions that exceed 2/10 in. (5 mm) from the blanking

band on the profiler trace.

The deck surface must then meet a 1/8 in. in 10 ft. (3 mm in 3 m) straightedge check made transversely.

Correct bridge decks and approach slabs that do not pass the Ride Quality Test as described in

Subsection 500.3.05.AG, Complete Corrective Work.

500.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

500.4Measurement

This work is measured for payment either per cubic yard (meter), per Lump Sum, or per linear foot (meter), whichever

is shown on the plans.

• Seal Concrete. The quantity of seal concrete to be measured for payment is calculated using the horizontal seal

dimensions specified on the Plans.

• Grooving. Grooving on bridge decks and approach slabs, completed acceptably according to

Subsection 500.3.05.T, Place Bridge Deck Concrete, step 9.c, will be measured and paid for by the square yard

(meter). Payment is full compensation for furnishing the necessary equipment and performing the Work.

• Class B Concrete. Class B concrete used for base and pavement widening will be measured and paid for by the

cubic yard (meter) complete in place and accepted.

500.4.01 Limits

There will be no separate measurement and payment for the following:

• Extra reinforcing

• Extra concrete

• Other costs incurred because of the requirements of this specification

All costs are included in the Lump Sum prices bid for superstructure concrete and

superstructure reinforcement. 665665665665665665

Measurement limits on payment per cubic yard (meter) are:

The quantity of concrete measured for payment is the algebraic summation of the Base Pay Quantity and

authorized quantity changes.

If additional quantities are necessary because of any of the following, these quantities are measured

separately for payment:

• Rocks were removed carefully but additional quantities are needed because footing depth and keyway

dimension are irregular from unanticipated rock removal.

• Voids or crevices exist within the spread footing area.

• The Engineer authorized filling trenches cut in rock outside footing areas to ease dewatering.

These additional quantities will be paid as filler concrete per cubic yard (meter).

When the Plans do not require a seal but a seal becomes necessary, or when the Plans do not show seal

dimensions, the maximum pay dimensions in each direction will be the Plan dimension of the structural

footing plus 3 ft. (1 m), with 18 in. (460 mm) on each side.

If the Contractor uses lesser dimensions, measurement is based on the lesser dimensions. Concrete placed

beyond the maximum pay limits are not measured.

For Lump Sum payment, determine the quantities required before submitting the bid.

The concrete quantity must conform to the Plan dimensions. Measurement is made as a unit, complete in place,

and includes the following:

• Diaphragms

• Sidewalks

• Concrete parapets

Measurement does not include concrete in the following items that will be paid for separately:

• Concrete handrailing

• Barriers

• Prestressed bridge members.

Payments for parapets placed by slip-form method is included in the Lump Sum price bid for

superstructure concrete.

Unless otherwise shown on the Plans, the cost of steel joints and metal bearing assemblies used in structures

where there is no structural steel Pay Item are included in the Contract Price for superstructure concrete.

Retaining wall incidentals will be measured for payment as follows:

Drainage items required by Special Plans are measured for payment by the unit specified on the plans only

when they are set up as specific Pay Items and are paid for separately. Otherwise, their costs are included in

the Contract Price for concrete.

Payment is full compensation for the costs of excavation and backfill necessary to place the drainage items

required by Special Plans.

The following are not measured for separate payment. Costs are included in the Contract Price for concrete.

• Sand blankets

• Crushed or broken stone

• Weep holes 666666666666666666

The following are not measured for separate payment. Costs are included in the Contract Price for concrete.

• Expansion material

• Rubber or polyvinyl plastic water stops

The cost of placing utility hardware items is included in the Contract Price for the class of concrete the items are

placed in.

500.5Payment

This Work will be paid for at the Contract Price per cubic yard (meter), per Lump Sum, or per linear foot (meter), each

complete in place and accepted.

Payment is full compensation for all things, including incidentals, and direct and indirect costs, to complete the Work.

Payment will be made under:

Item No. Item Payment

Superstructure concrete class_____, Bridge no._____ Per lump sum

Concrete handrailing (designation) Per linear foot (meter)

Class_____concrete Per cubic yard (meter)

Class_____concrete, high-early strength Per cubic yard (meter)

Seal concrete Per cubic yard (meter)

Class B concrete base or pavement widening Per cubic yard (meter)

Class_____concrete including reinforcement steel Per cubic yard (meter)

Class A concrete—filler Per cubic yard (meter)

Class_____concrete—retaining wall Per cubic yard (meter)

Grooved concrete Per square yard (meter)

Concrete barrier Per linear foot (meter) 667667667667667667

500.5.01 Adjustments

Assume the following costs:

measures requested by the Engineer unless the fault lies solely with the Department

The Department will conduct ride quality testing of bridge decks and approach slabs only twice per bridge at no

cost to the Contractor.

The Department will conduct additional ride quality testing at the cost of $2000 per test.

The Department may issue a pay reduction based on the square yards (meters) of the span not passing the

required 15 in./mi (235mm/km), and not having any bumps or depressions greater than 2/10 in. (5mm) required in

Subsection 500.3.06.E. This pay reduction will be calculated based on SOP 48 for Bridge and Approach

Penalties. A minimum of $1500.00 per bridge will be assessed for any pay reductions.

The Engineer will determine how to repair cracks caused by plastic shrinking. Repair cracks at no cost to

the Department.

For all bridges (except seal concrete), concrete culverts, headwalls, and retaining walls, the quantities shown on

the Contract Plans, including Standard Plans, will be considered the Base Pay Quantity.

For seal concrete, the Plan quantities are approximate and are for estimating purposes only. The quantities will not

be considered as Base Pay Quantities.

Calculated additions or deductions will be applied to the Base Pay Quantity when the Engineer makes authorized

changes. Changes include, but are not limited to, authorized changes in the following:

• Footing dimensions

• Lengthening or shortening of concrete culverts

• Correcting Plan Quantities

• Dimension errors

• Multi-barrel culvert wall thicknesses

• Lengthening or shortening bridge columns

• Raising or lowering foundations 668668668668668668

Calculations of the Base Pay Quantity and any changes will be made as follows:

individual areas are less than 1 in.² (645 mm²).

The volume of concrete in fillets of the same area will be neglected.

(0.07 m³/linear meter) of pile.

• Steel reinforcement

• Shear connectors

• Floor drains (unless they are paid for as separate Pay Items)

• Incidentals such as expansion material

• Joint sealing compound

• Utility thimbles and hangers

Filler concrete, measured as described in Subsection 500.4.01.B.1, Bridges, Concrete Culverts, Headwalls, and

Retaining Walls, will be paid at 40 percent of the Contract Price per cubic meter for Class A Concrete or

Class AA Concrete.

If there is no Contract Price for seal concrete, payment will be per cubic yard (meter), measured as described in

Subsection 500.4.01.B.2, Seals, and will be paid at 60 percent of the Contract Price per cubic yard (meter) for

Class A concrete.

Adjust the payment as follows:

When authorized changes are made as described in Subsection 500.5.01.D, Plan Quantities, the lump sum

payment may be adjusted on a pro rata basis or according to Section 104 and as determined by the Engineer.

The Plans show tabulated quantities as a service. This does not relieve any responsibility to conform to

plan details.

If exercising an optional Plan feature, the Base Pay Quantity will not be changed if it is the only quantity

change involved.

However, if other changes are necessary, the quantity change resulting from the optional feature will be

considered in the necessary quantity adjustments.

When the falsework is completed for post-tensioned box girder bridges, 20 percent of the Lump Sum

superstructure concrete price will be paid.

Additional payments made as the concrete is placed must be adjusted for the payment for falsework. In other

words, payment for concrete placed will be based on 80 percent of the superstructure bid price.

Superstructure Concrete price will be made. For Post-Tensioned Box Girder Bridges, this percentage (5%) will

apply to that part of the superstructure 669 669 669 669 669 669