915BRIDGE PILES AND BEARINGS

915.01Steel Pipe Piles and Epoxy Coated Steel Pipe Piles

Steel pipe piles and epoxy coated steel pipe piles, as designated herein, shall consist of fluted steel, or rounded straight seamed, spiral seamed, or seamless steel pipes which, after being driven are filled with class A concrete. The steel pipe shall be uncoated unless an epoxy coating, in accordance with 915.01(d) is specified.

Pipe piles shall be of the diameter and minimum wall thickness shown on the plans. All sections shall be one cylindrical integral piece except as otherwise required for end sections of the outside diameter specified. All pipe piles shall be of sufficient strength to withstand driving to the required penetration depth and nominal driving resistance.

If necessary to facilitate handling, pipe piles may be furnished in sections to be welded in the field to form the final integral lengths required.

The manufacturer shall provide a mill certification showing heat numbers and test 20 results for the specified tests. Each pipe pile shall be stenciled to show the diameter, wall thickness, and heat numbers for the verification of the certifications. The certifications shall be delivered before the pipe piles are driven.

The end of pipe piles shall be equipped with conical pile tips or flat end plates. The welding used to attach th e conical pile tips or flat en d plates to the end of pipe piles shall be done by a welder qualified in accordance with 711.32.

915.01

If end plates are used, they shall be fl at, non-reinforced and a minimum thickness 30 of 3/4 in. for pipe piles 12 in. outside diameter or smaller, and 1 in. thick for pipe piles greater than 12 in. outside diameter up to and including 14 in. For pipe piles larger than 14 in. outside diameter, the end plates shall be designed to complement the size of the pipe pile. End plates shall have a diameter approximately 1/2 in. greater than the outside diameter of the pipe pile and be fillet welded to the pipe pile, using two passes or beads.

Conical pile tips shall be of sufficient dimensions to ensure adequate joint and driving strength. The end of the pipe pile shall have full bearing on the face of the pile 40 tip or against a shoulder inside the pile tip. Unless otherwise approved, the pile tip shall be conical with a 60 to 90° angle between faces. The pile tip shall be substantially of the same diameter as the end of the pipe pile and butt welded to the end of the lowest section.

Fluted steel pipe piles shall have a minimum tensile strength of 50,000 psi when tested in accordance with AS TM A370. Test specimens for determination of tensile strength shall be taken longitudinally adjacent to the crest of the flute. The diameter of fluted steel pipe piles shall be measured from crest to crest of flutes. 50

A sufficient taper will be allowed to enable no less than 6 in. telescoping at the joints. The lowest section shall taper approximately 1 in. in 4 ft from an 8 in. tip to the specified diameter of the upper end. Fluted steel pipe piles with a taper of 1 in. in 7 ft on the lowest section of long piles may be used provided a minimum of approximately 5 ft of the top of the pile below cutoff elevation is the full diameter as shown on the plans.

Rounded steel pipe piles, except for end finish, shall be in accordance with 60 ASTM A252, grade 3. Welded pipe may be welded with straight or spiral seams.

Only powdered epoxy resin from the QPL of Epoxy Coating Materials shall be used for the epoxy coating of steel pipe piles and steel H piles.

The patching or repair material shall be compatible with the coating and shall be made available by the coating manufacturer. The material shall be suitable for repairs made to coated areas damaged during fabrication or handling.

The coating color shall contrast with the color of iron oxide. All coated piles furnished for a structure shall be the same color. The patching or repair material shall also be the same color as the original coating material.

915.01

The coating product shall be 100% solids, heat curable, thermosetting, dry powdered epoxy coating. Coating manufacturers who request to have their product added to the QPL of Epoxy Coating Materials shall supply the information as follows.

A product data sheet which shall specify the method of surface preparation, the thermal treatments before and after coating application, the coating application procedure, and the product name and description of the patching material shall be provided.

The fingerprint shall include the method of test, such as infrared spectroscopy or thermal analysis, and a generic description of the product.

Current materials safety data sheets shall be supplied for the product and the patching material.

A dated laboratory report shall be provided which substantiates full compliance with the following test requirements.

The tensile strength and elongation of the coating material shall be tested in accordance with ASTM D2370 with a rate of elongation of 10% to 20% per minute. 100 The minimum tensile strength shall be 8,000 psi. The minimum elongation shall be 5%.

The impact resistance of the coating shall be tested in accordance with ASTM G14 using a 0.03 mm minimum coating thickness of a 3.2 mm thick panel at 23°C. Three tests shall be performed. The minimum acceptable value shall be 9.0 N m. of impact with no visible breaks in the coating.

The abrasion resistance of the coating sh all be tested in ac cordance with the Annex to ASTM A972.

The weathering resistance of the coating shall be tested by means of a salt spray cabinet following ASTM B117 for 1,000 h. The coating shall not blister or exhibit corrosion, discoloration, or loss of adhesion away from the scribed area.

The application of the epoxy coating shall be at an enclosed plant, equipped with 120 environmental controls and automated blasting equipment. This equipment shall 915.01

facilitate surface preparation and coating application in accordance with the manufacturer’s recommendations and in accordance with additional requirements set out herein. The application process shall be performed by a continuous, balanced system where cleaning of the surface and app lication of the coating are performed at the same rate.

The pile surface shall be blast cleaned in conformance with SSPC-SP-10, Near White Metal Blast. The cleaning media shall produce an anchor pattern profile of 130 2 mils minimum. All raised slivers, scabs, laminations, or bristles of steel remaining on the newly cleaned surface shall be removed by means of abrasive sanders. All traces of grit and dust from the blasting shall be removed.

The coating shall be applied immediately to the cleaned surface and before visible oxidation of the surface occurs. The coating shall be applied in accordance with the manufacturer’s recommendations. The recommendations shall address the equipment required for proper application, the number of coats of epoxy, cure time between coats, cure time before placing in service, and all other information needed by the 140 Department to ensure proper performance of the material.

Thickness of the cured coating shall be measured on a representative number of piles from each production lot by the same method required by ASTM G12 for measurement of film thickness of pipeline coatings on steel. The minimum coating thickness for fusion bonded epoxy shall be 8.0 mils for individual measurements and 12 mils for the average.

The coating film shall be cured a nd post cured in accordance with the manufacturer’s recommendations. A representative proportion of each production lot shall be checked by the coating applicator using a method found most effective for measuring cure to ensure that the entire production lot is in a fully cured condition.

After cure, the epoxy coating shall be checked by the applicator for continuity of coating and shall be free from holes, voids, contamination, cracks, and damaged areas. There shall not be more than two holidays, which are pinholes not visually discernable, in any linear foot of the co ated pile. A holiday detector in accordance with ASTM 160 A972 shall be used in accordance with the manufacturer’s instructions to check the coatings for holidays.

A Type C certification in accordance with 916 shall be provided for the epoxy coating. In addition, a certi ficate of compliance prepared by the applicator shall be provided for each shipment of coated piles. The certificate of compliance shall state 915.01

that the piles have been coated in accordance with the manufacturer’s requirements; that thickness, continuity, and flexibility tests of the coating have been performed; and that the test results are in accordance w ith the requirements outlined herein. Test 170 results shall be retained by the applicator and made available for inspection upon request for a period of seven years.

915.02Steel H Piles and Epoxy Coated Steel H Piles

Steel H piles and epoxy coated steel H piles shall be of the shape and dimensions shown on the plans or as otherwise specified. The steel shall be in accordance with ASTM A572, grade 50. Steel H piling shall be handled in the same manner as required in 711.56. The piles shall be uncoated unless an epoxy coating, in accordance with

(d), is specified

The manufacturer shall provide a mill certification showing heat numbers and test results for the specified tests. Each H pile shall be stenciled to show the manufacturer’s name, the specifications, size and mass of s ection, and heat numbers for verification of the certification. The certification shall be submitted at the time of delivery of the piles.

915.03Pile Shoes

A Type C certification in accordance with 916 shall be provided for the steel H pile shoes. Pile shoes shall be cast-in-one-piece steel in accordance with ASTM A148, grade 80-50 and shall be fastened to the piles by welding in accordance with the 190 manufacturer’s recommendations. They shall have sufficient flange and continuous web vertical back-ups to assure proper alignment and fitting to the pile. Either the pile shoe or the outside of each flange of the pile shall be beveled 45°. E70XX welding rods shall be used. All welds shall be made in the flat position and the welder shall be qualified in accordance with 711.32.

A Type C certification in accordance with 916 shall be provided for the timber pile shoes. Pile shoes shall be cast-in-one-piece steel in accordance with ASTM A27, grade 65-35, class 2 or grade 70-36, class 2 and shall be fastened to the piles in accordance with the manufacturer’s recommendations. 200

The soil or rock bearing surfaces of the shoes shall be sloped downward towards the web a minimum of 15° but not to exceed 45° to the horizontal under the flanges. The sloped surfaces of the shoes shall term inate to form a flat surface not exceeding 1/3 of the flange width. The surfaces may have individual or continuous cutting teeth.

915.04Elastomeric Bearings

Elastomeric bearings as herein specified shall include plain bearings, consisting 210 of elastomer only, and laminated bearings, consisting of layers of elastomer restrained

at their interfaces by bonded laminates. The bearing type shall be as shown on the

plans.

915.04

1118

Elastomeric bearing pads shall be made from elastomeric materials and shall be

steel reinforced as shown on the plans. They shall be in accordance with Articles 18.1

and 18.2 of the AASHTO LRFD Bridge Construction Specifications and AASHTO M220

251 with the exception that Table X1 is not applicable. The elastomer portion of the

elastomeric compound shall be 100% virgin natural polyisoprene known as natural

rubber, or 100% virgin polychloroprene known as neoprene. The cured compound

shall be in accordance with Table A for natural rubber, or Table B for neoprene,

depending on which type is furnished.

[continued on next page]

915.04

1119

TABLE A

POLYISOPRENE, OR NATURAL RUBBER, QUALITY CONTROL TESTS

PHYSICAL PROPERTIES

ASTM D2240 Hardness (Durometer Type A) 55 ±5

ASTM D412 Tensile Strength, min., ksi 2.25

Ultimate Elongation, min. % 425

HEAT RESISTANCE

ASTM D573,

70 h, @ 158ºF

Change in Durometer Hardness,

max. points

Change in Tensile Strength, max. % -25

Change in Ultimate Elongation, max. % -25

COMPRESSION SET

ASTM D395,

Method B 22 h @ 158ºF, max. % 25

OZONE

ASTM D1149

25 ppm ozone in air by volume,

20% strain, 100ºF ±2ºF, 48 h mounting

procedure, D 518, Procedure A

No Cracks

LOW-TEMPERATURE BRITTLENESS

ASTM D746,

Procedure

9.1.2

Grades 0 and 2

Grade 3, Brittleness @ -40ºF No Failure

INSTANTANEOUS THERMAL STIFFENING

ASTM D1043

Grades 0 and 2, Tested @ -32ºC Stiffness at test temperature

shall not exceed four times the

stiffness measured at 74ºF.

Grade 3, Tested @ -40ºF

LOW-TEMPERATURE CRYSTALLIZATION

Quad Shear

Test as

Described

Grade 3, 14 Days @ -15ºF

Stiffness at test time and

temperature shall not exceed

four times the stiffness

measured at 74ºF with no time

delay. The stiffness shall be

measured with a quad shear test

rig in an enclosed freezer unit.

The test specimens shall be

taken from a randomly selected

bearing. A ±25% strain cycle

shall be used. A complete cycle

of strain shall be applied within

a period of 100 s. The first 0.75

cycle of strain shall be

discarded. The stiffness shall be

determined by the slope of the

force deflection curve for the

next 0.50 cycle of loading.

915.04

1120

TABLE B230

POLYCHLOROPRENE, OR NEOPRENE, QUALITY CONTROL TESTS

PHYSICAL PROPERTIES

ASTM D2240 Hardness (Durometer Type A) 55 ±5

ASTM D412 Tensile Strength, min., ksi 2.25

Ultimate Elongation, min. % 375

HEAT RESISTANCE

ASTM D573,

70 h, @ 212ºF

Change in Durometer Hardness,

max. points

Change in Tensile Strength, max. % -15

Change in Ultimate Elongation, max. % -40

COMPRESSION SET

ASTM D395,

Method B 22 h @ 212ºF, max. % 35

OZONE

ASTM D1149

25 ppm ozone in air by volume, 20%

strain, 100ºF ±2ºF, 48 h mounting

procedure, D 518, Procedure A

No Cracks

LOW-TEMPERATURE BRITTLENESS

ASTM D746,

Procedure 9.1.2 Grade 3, Brittleness @ -40ºF No Failure

INSTANTANEOUS THERMAL STIFFENING

ASTM D1043 Grade 3, Tested @ -40ºF

Stiffness at test temperature shall

not exceed four times the

stiffness measured at 74ºF.

LOW-TEMPERATURE CRYSTALLIZATION

Quad Shear Test

as Described Grade 3, 14 Days @ -15ºF

Stiffness at test time and

temperature shall not exceed four

times the stiffness measured at

74ºF with no time delay. The

stiffness shall be measured with a

quad shear test rig in an enclosed

freezer unit. The test specimens

shall be taken from a randomly

selected bearing. A ±25% strain

cycle shall be used. A complete

cycle of strain shall be applied

within a period of 100 s. The first

0.75 cycle of strain shall be

discarded. The stiffness shall be

determined by the slope of the

force deflection curve for the

next 0.50 cycle of loading.

915.04

1121

The bond strength, determined in accordance with ASTM D429, Method B, shall

be at least 40 lb/in.

The adhesion failure, determined in accordance with ASTM D429, Method B,

shall be at least R-80. The adhesion-failure requirement will be waived if the bond

strength is at least 80 lb/in.

Structural steel spacer plates, top and bottom load plates, and other steel

components, including anchor bolts, exposed to the environment shall be galvanized

in accordance with AASHTO M 111, zinc metallized with a coating of 7 mils in

accordance with SSPC-CS 23.00, or painted with the structural steel coating system in

accordance with 619.09(a). The finish coat for painted steel shall be in accordance

with 909.02(d). The color shall be in accordance with SAE-AMS-STD-595, color No.

20045.

When stainless steel load plates are specified, the material shall be in accordance

with ASTM A240, Type 304.250

Internal steel shims shall be rolled hot and cold steel and shall be in accordance

with AISI 1015 through 1025, ASTM A1008, or ASTM A1011 grade 36 or higher.

Shims shall be of the thickness specified with a tolerance of ±0.015 in.

Threaded studs, where required, shall be in accordance with ASTM A307 and

mechanically zinc coated in accordance with ASTM B695, class 50.

260

Side retainers shall be made from plates or rolled mild steel in accordance with

ASTM A36.

Plain bearings may be molded individually, cut from previously molded strips or

slabs, or extruded and cut to length. Cut edges shall be at least as smooth as

ANSI B 46.1 No. 250 finish. Unless otherwise shown on the plans, all components of

a laminated bearing shall be molded together into an integral unit. Air bubbles within

the elastomeric material shall be cause for rejection.270

Laminated elastomeric bearings shall be individually molded to the required size.

Corners and edges may be rounded with a radius at the corners not exceeding 3/8 in.

and a radius at the edges not exceeding 1/4 in.

Steel shims shall be sandblasted and cleaned and protected against contaminants

until fabrication is completed.

915.04

1122

Bearings designed as a single unit shall be built as a single unit.

280

Each reinforced bearing shall be marked with indelible ink or flexible paint. The

marking shall consist of the orientation, the order number, lot number, bearing

identification number, and elastomer type and grade number. Unless otherwise

specified, the marking shall be on a face that is visible after erection of the bridge.

Where load plates are shown on the plans, the bearing shall be vulcanized to the

steel load plate during the primary molding process.

The edges of the embedded steel laminates, including around holes, shall be290

covered with 1/8 to 1/4 in. of elastomer. All other dimension tolerances shall be in

accordance with AASHTO M 251.

The mechanical properties of the materials and of the finished bearing shall be in

accordance with the AASHTO LRFD Bridge Construction Specifications, Article

18.2.5, and AASHTO M 251, with the exception that the tables in 915.04(b)1 shall be

used.

shall not exceed 7% at 800 psi average unit pressure or at

the design dead load plus live load pressure if shown on the

plans.

for 55 durometer, table A compounds; or 75 psi for 55

durometer, table B compounds at 25% strain of the total

effective rubber thickness after an extended four-day

ambient temperature of -20°F.

310

A Type B certification in accordance with 916 shall be provided for the

elastomeric bearings. The limits of the following shall be shown on the certification:

915.04

1123

Test ASTM or INDOT Standard

Specifications

Ultimate Tensile Strength D412

Ultimate Elongation D412

Hardness (Durometer) D2240

Tensile Strength and Elongation

on Oven-aged Material D573 and D412

Hardness on Oven-aged Material D573 and D2240

Compression Set D395, Method B

Ozone Resistance D1149

Adhesion D429, Method B

Brittleness D746, Procedure 9.1.2

Compressive Strain 915.04(e)1

Shear Resistance 915.04(e)2

When steel components are incorporated into elastomeric bearings, a mill

certification, galvanization certification, if applicable, and a Buy America

Certification in accordance with 106.01(c) will be required.

In addition, one bearing pad from each type to be furnished for the structure will320

be required for laboratory testing. A type of bearing is defined by the length, width,

and thickness of elastomer, and the number and thickness of internal shims. Bearings

that differ by the dimensions of load plates vulcanized to similar elastomeric pads will

also be considered different types. The material may be sampled prior to shipment to

the project, provided suitable arrangements can be made through the Department’s

Division of Materials and Tests. Materials not previously sampled and tested shall be

sampled for testing after delivery to the project site. Samples shall be furnished for

testing at least 30 days before date of use. Passing test results will be required prior to

using the material.

330

915.05Bearing Assemblies with Polytetrafluoroethylene, PTFE, Sliding

Surfaces

A copy of the manufacturer’s design manual shall be submitted for approval when

directed.

All steel components shall be in accordance with ASTM A709, grade 36 unless

otherwise shown on the plans. Where these assemblies are used in conjunction with

weathering steel, the steel components shall be in accordance with ASTM A709, grade

50W. Stainless steel mating surfaces shall be 14 gauge minimum ASTM A240, Type

304 sheets with a maximum surface roughness of 20 Rms.340

The PTFE shall be 100% virgin unfilled polymer or 15% glass filled and etched

on the bonding side. The properties of the PTFE shall be in accordance with the

following:

915.05

1124

Requirement Test Method Value

Tensile Strength, minimum ASTM D638 2,500 psi

Elongation, %, minimum ASTM D638 200

Specific Gravity ASTM D792 2.1 to 2.3

PTFE, where required, shall be virgin material, etched on the bonding face and in

accordance with ASTM D 4894. The PTFE shall be bonded to grit blasted steel in

accordance with Federal Specification MMM-A-134, Type 1. The elastomeric pad

shall be vulcanized to the steel load plate during the primary molding process. The350

stainless steel sliding plate shall be seal welded to the steel load plate.

All steel surfaces exposed to the environment shall be zinc metalized and shall be

7 mils thick in accordance with SSPC-CS 23.00 or painted in accordance with

619.09(a). The finish coat for painted steel shall be in accordance with 909.02(d). The

color shall be in accordance with SAE-AMS-STD-595, color No. 20045.

A Type B certification in accordance with 916 shall be provided for the bearing

assemblies. The limits of the above shall be shown on the certification.