733 – BRIDGE DRAINAGE SYSTEMS & DECK DRAIN EXTENSIONS remove glossy finish and expose fibers . Insert pipe so it bottoms out within the bell fitting to create a fully fitted joint. Mix and apply 2 layers of adhe sive according to the manu factures recommendations. Secure the joint so it cannot move, do not twist the joint. Do not disturb the joint until it has gelled according to the manufactures recommendations. An electric heat gun or heating co llar may be used to accelerate gelation of the joint.
1 ¾-inch long by ½ -inch diameter bolts with a flat washer and lock nut. Place the bolt head on the inside of the PVC pipe. Anchor the steel angles to the bottom of the deck using a concrete hex nut sleeve anchor. Use a 5/8-inch diameter sleeve anchor with an effective anchor length of 2 ½ inches and a bolt with a ½-inch diameter. Embed all anchors a minimum of 2 inches into the bottom of the concrete. Drill and place the anchors in accordance with the anchor manufacturer's recommendations. Plumb the completed drain extension and place the PVC pipe flush against the bottom of the concrete. Use PVC pipe lengths that extend a minimum of 12 inches below the bottom of the beam, girder, chord or slab. If the beam, girder, chord or slab is not of uniform de pth, vary the length of each ex tension to provide the 12-inch minimum.
733.4MEASUREMENT AND PAYMENT
The Engineer will measure bridge drainage system by the units shown in the Contract Documents. The Engineer will measure each bridge deck drain extension. Payment for "Bridge Drainage System" and "Bridge Deck Drain Extension" at the contract unit prices is full compensation for the specified work. 734 - STRUCTURAL PLATE STRUCTURES
700-124SECTION 734
STRUCTURAL PLATE STRUCTURES
734.1DESCRIPTION
Assemble and install the size and ty pe of structural plate structure sp ecified in the Contract Documents.
B I D I T E M S U N I T S (*) Structural Plate Pipe (* *) (***) Linear Foot (*) Structural Plate Pipe Arch (**) (***) Linear Foot (*) Structural Plate Arch (**) (***) Linear Foot *Size, diameter or span and height **Gauge ***Asphalt Coated
734.2MATERIALS
Provide structural plate for pipe, pipe arches and arches that comply with DIVISION 1900 .
734.3CONSTRUCTION REQUIREMENTS
Submit the design to the Engineer for approval, be fore installing any struct ural plate structure. Include a Load Rating Table on the working drawings and provide the SBO with a LFR and LRFR rating and support calculations for the structure. The load ra ting shall take into consideration varying fill depths and KDOT live load criteria. For LFR Load Rating, include HS-20-44, KDOT rating vehicles for Inventory and Operating rating factors. Rate the Heavy Equipment Tr ansport (HET) vehicle for Op erating rating factor. For LRFR, use HL-93 for Inventory and Operating. Submit a Load Rating Report along with the working drawings. Include in the Load Rating Report a summary rating table, assumptions used in the load rating, the depth of fill, material strengths and any other signif icant information required to load rate the precast culvert. The Load Rating will include all elements of the proposed system incl uding, but not limited to stub-walls and connections. If the Contract Documents require a concrete footing, construct the footing according to DIVISION 700 . Excavate for and form the bed for the st ructural plate structures according to DIVISION 200 . If placing 2 or more structural plate structures adj acent to each other, separate them by a distance equal to ½ the diameter of the pipe for structural plate pipe, and by a distance of 2 feet for structural plate pipe arch. Do not damage the plates during assembly and erection. Replace plates that are damaged during shipping or assembly. Repair any damaged coating after erection Assemble the structural plate structure true to the dimensions shown in the Contract Documents, with all connections tight. When required by the Contract Documents, provide and erect strutting within the structure during construction, leaving it in place until the structure is backfilled. Backfill the structure according to DIVISION 200 .
734.4MEASUREMENT AND PAYMENT
The Engineer will measure structural plate structure by the linear foot, along the centerline of the structure. The Engineer will measure structural plate structures with ve rtical ends from end to end. The Engineer will measure structural plate structures with sloping ends from the center point of the slope on one end to the center point of the slope on the opposite end. Payment for the "Structural Plate Pipe", "Structural Plate Pipe Arch" and "Structural Plate Arch" at the contract unit prices is full comp ensation for the sp ecified work. 735 - PRECAST REINFO RCED CONCRETE BOX
700-125SECTION 735
PRECAST REINFORCED CONCRETE BOX
735.1DESCRIPTION
Install the specified sizes of precas t reinforced concrete boxes at the lo cations designated in the Contract Documents. Unless specified otherwise in the Contract Documents, the Contractor has the option to substitute precast reinforced concrete boxes for the cast-in-place reinfor ced concrete boxes shown in the Contract Documents. Submit all working drawings according to SECTION 105 .
B I D I T E M U N I T S Reinforced Concrete Box (*) (Precast) Linear Foot *Size
DESIGN: Design the precast concrete box units in accordance with the AASHTO LRFD Bridge Design Specifications, latest version. Precast wings and headwalls are prohibited at stream crossings. Cast-in-place end sections shall conform to KDOT Standard BR031.
For fill heights less than or equal to 3 feet: Use epoxy coated reinforcing steel and air entrained concrete Use a distribution slab meeting the requirements of KDOT Standard BR031. Use an approved “non-coal tar” bridge backwall protection system to cover the middle 1/3 of the top of precast arch culverts, the complete top slab of precast rigid frame culv erts and the uppermost 12 inches of the outside walls. Indicate on the shop drawings the limits of the bridge backwall protection system.
Prior to beginning foundation construction, submit complete design calculations, including loadings, for the Engineer’s review. Design calculations and loadings may be submitted prior to the working drawing submittal. Submit design calculations sealed by a Kansas licensed Professional Engineer. Prior to fabrication, submit to the Engineer for review and approval, working drawings including the supplier’s manufacturing specifications, details of all phases of construction, including layout, joint details, lifting devices, casting methods, construction pl acement and details of any cast-in-place sections. Submit working drawings according to SECTION 105 . Designate proposed transportation methods, and submit over-height and overload permits, if required, with the working drawings. When required, submit falsework plans and calculations sealed by a Kansas licensed Professional Engineer according to SECTION 708 . PRECAST CONCRETE BOX LOAD RATING: Include a Load Rating Table on the working drawings and provide the State Bridge Office with a LFR and LRFR rating and support calculations for the structure. Th e load rating shall take into consideration varying fill depths and KDOT live load criteria. For LFR Load Rating, include HS-20-44, KDOT rating vehicles for Inventory and Operating rating factors. Rate the Heavy Equipment Transport (HET) vehicle for Op erating rating factor. For LRFR, use HL-93 for Inventory and Operating. Submit a Load Rating Report along with the working drawings. Include in the Load Rating Report a summary rating table, assumptions used in the load rating, the depth of fill, material strengths and any other signif icant information required to load rate the precast culvert. The Load Rating will include all elements of the proposed system incl uding, but not limited to stub-walls and connections.
735.2MATERIALS
Grade 4.0 and 4.0 (AE) Concrete .......................................................................... SECTIONS 401 & 402* Commercial Grade Concrete for Seal Course ........................................................ SECTIONS 401 & 402 735 - PRECAST REINFO RCED CONCRETE BOX
700-126Aggregate for Concrete Not On Grade .................................................................. SECTION 1102
Reinforcing Steel (Grade 60) ................................................................................ DIVISION 1600 Reinforcing Steel (Epoxy Coated) (Grade 60) ...................................................... DIVISION 1600 Welded Wire Fabric .............................................................................................. DIVISION 1600 Quality Control Program for Precast Concrete Products ........................................ DIVISION 1900 Drilling and Grouting …… ………………………………… …………………...... DIVISION 800 Joint Seals……………………………………….………………………………… DIVISION 1500 Geotextile Fabric .................................................................................................... DIVISION 1700 Bridge Backwall Protection…………… …………………………………………. DIVISION 1700 *For precast reinforced concrete boxes constructed acc ording to this specificati on, KT-73 testing is not required.
ASTM C 1577 and this specification. Exceptions and additions to the above requirements are: (1) ASTM Section 11. PERMISSIBLE VARIATIONS. Revise the first sentence of subsection 11.1 to read: The internal dimensions may not vary more than 1% or ¾ inch, whichever is less, from the design dimensions.
Continue joining each unit until production is satis factory. Check appr oximately 10% of the remaining production at random, using a minimum 3 unit assembly. The Engineer may order a 3 or more unit assembly at any time measurements or observations indicate a problem exists.
single-cell precast boxes. (4) Member thickness shall be the thickness specified by ASTM C 1577, ¾ the thickness of the corresponding member of an equivalent KDOT Standard cast-in-place rigi d frame box culvert, or six inches, whichever is larger. When calculating the minimum thickness of the bottom slab , deduct ½ inch from the cast-in-place thickness before factoring by ¾.
fill is less than 2 feet. In that case, make the clearance in the top of the top slab 2 ½ inches ± ¼ inch. Develop all reinforcement according to the AASHTO LRFD Bridge Design Specifications.
approved “non-coal tar” “Bridge Backwall Protection System” to cover the top slab and uppermost 12 inches of the outside walls. Indicate on the shop drawing which option was used.
temperature requirements in each face, except at the joint as shown in th e Contract Documents.
fabric.
where the depth of fill will be less than 2 feet , as shown in the Contract Documents.
or equal to 6 feet. Do not modify the cell height shown on the Contract Documents, unless approved by the Engineer. Two single-cell boxes may be substituted for a double-cell box, when approved by the Engineer.
all phases of construction including layout, joint details, lifting devices, casting methods, construction placement and details of any cast-in-place sections. Note the prop osed transportation methods on the working drawings.
approved means: Date of manufacture; Name or trademark, and location of the manufacturer; 735 - PRECAST REINFO RCED CONCRETE BOX 700-127 Weight of box section in tons; and The top of the box.
Allow the Engineer free access to the manufacturing plant at all times for the purpose of inspecting materials, plant facilities and manufacturing and curing procedures. Inform the Engineer of planned concrete placement and curing schedule 5 business days before work is started. Precast reinforced concrete boxes will be accepted according to SECTION 1902 , and when deemed necessary by the Engineer, satisfactory results of mate rial tests performed by th e Engineer, compliance with dimensional requirements and visual inspection at the point of production or usage.
foundation of the precast box. Provide crushed stone free of soapstone, shale, shalel ike or other easily disintegrated material. Provide crushed stone with adequate gradation to provide a uniform foundation. The E ngineer will accept the crushed stone based on visual inspection at the point of usage. For concrete seal course, provide commercial grade concrete, or use any other concrete acceptable for use on the project.
735.3CONSTRUCTION REQUIREMENTS
a 6-inch (minimum) thickness of crushed stone, or 3 inches of concrete seal course of commercial grade concrete for the foundation of the precast box.
each section up-grade. Join the sections tightly.
Documents. Install the joint sealant according to the manufacturer’s recommendations. If geotextile is used to wrap the joint: Use only geotextile that has been properly stored; Limit the exposure to the elements (between placement and covering) of the geotextile to a maximum of 7 calendar days; Do not drop any D 50 backfill larger than 6 inches onto the geotextile from a height greater than 1 foot; Do not drop any D 50 backfill smaller than 6 inches onto the geotextile from a height greater than 3 feet; and Do not contaminate the geotextile with grease, mud or other foreign substances. Replace contaminated or damaged geotextile. If approved by the Engineer, re pair damaged geotextile by placing a patch over the damaged area and sewing the patch to the geotextile. Extend the patch a minimum of 1 foot beyond the perimeter of the damaged area. Replace contaminated or damaged geotextile, or repair if approved, at the Contractor’s expense.
Fill the lifting holes with precast plugs sealed with mastic or mortar.
heights less than 2 feet but greater than 1 foot, otherwise use cast-in-place. Construct or place the distribution slab to extend a minimu m of 2 feet beyond the exterior walls of the barrel. Construct or place the distribution slab to the outside edge of the roadway shoulders. Place a minimum of 3 inches of granular material between the box and a concrete distribution slab. Cast-in-place distribution slabs require one of the following combinations of steel reinforcement: 1 layer of mesh and 1 layer of reinforcement bars, or 1 layer of reinforcement bars.
735 - PRECAST REINFO RCED CONCRETE BOX
700-128Construct a cast-in-place distribution slab a minimum of 6 inches thick, reinforced with #4 bars spaced at 18
inches placed transverse to the centerline of the box, an d #5 bars spaced at 12 inches pl aced parallel to the centerline of the box. Uniformly consolidate the conc rete without voids. An equivalent welded wire fabric is acceptable.
Use the cast-in-place criteria above. Use precast distribution slab sections constructed with the same criteria as th e cast-in-place distribution slab above. Do not locate precast sl ab joints near precast box joints. Reinforced concrete pavement with reinforcement as specified for a cast-in-place slab mentioned above (minimum 6 inches thick) shall meet the requirements of a distribution slab. Asphalt pavement (minimum 6 inches thick) shall m eet the requirements of a distribution slab with 6 inches of granular material provided between the as phalt and the precast box. Place a geogrid on top of the granular material.
at horizontal and vertical changes in RCB alignment. Construct the cast-in-place sections, en d sections and wingwalls, according to DIVISION 700 , and as detailed in the Contract Documents. Construct the cast-in-place box sections at a mini mum to the member thickn esses and reinforcement shown in the Contract Documents. When the th icknesses between the cast-in-place and precast members are different, transition at a maximum rate of 4:1 without reducing the box opening size. Skewed precast structures with fill he ights greater than 10 feet will not be attached to the cast-in-place end section(s). Do not drill and grout dowel bars in the field, but detail on the working drawings and install by the Fabricator. Use 16 foot minimum cast-in-place en d section for structures where pr ecast sections are not attached (unreinforced open joint) to the cast-in-place sections. For multiple precast sections placed on a skew, submit for approval by the Engi neer, working drawings (sealed by a Kansas licensed Professional Engin eer) with details of cast-in-place end sections. When the thicknesses between the cast-in-place and precast members are different, transition at a maximum rate of 4:1 without reducing the box opening size.
slab and the uppermost 12 inches of the outside walls and both sides of the joint with a Bridge Backwall Protection System from the KDOT's prequalified list. Remove any dirt or latent concrete before applying the coating per the manufactures directions. Lap ends and stagger joints acco rding to the manufacture’s recommendation. Repair any flaws or damage to the coating before backfilling the structure.
735.4MEASUREMENT AND PAYMENT
The Engineer will measure precast reinforced concrete boxes by the linear foot. Precast end sections, and cast-in-place end sections and wingwalls will not be measured for payment. When shown as a bid item in the contract, foundation stab ilization and concrete seal course will be measured and paid for according to SECTION 204 . When not shown as a bid item in the contract, foundation stabilization and concrete seal course are subsidiary. Payment for "Reinforced Concrete Box (Precast)" at the contract unit price is full compensation for the specified work. When not shown as a bid item in the contract, the "Bridge Backwall Protection System" will be subsidiary to other bid items. If constructed as an option to cast-in-place RCB’s, the Engineer will not measure the precast reinforced concrete boxes for payment. The cast-in-place quantities ar e the basis of payment. Payment of the cast-in-place quantities at the contract unit prices is full compensation for the specified work. 736 – PRECAST CULVERTS
700-129SECTION 736
PRECAST CULVERTS
736.1DESCRIPTION
Design, provide and install precast cu lvert units as shown in the Contra ct Documents. Do not substitute Precast Culvert elements with cast-in-place culvert elements without approval from the St ate Bridge Office (SBO).
BID ITEMS UNITS Precast Arch Culvert Linear Foot Precast Rigid Frame Culvert Linear Foot
DESIGN: Design the precast culvert units in accordance with the AASHTO LR FD Bridge Design Specifications, latest version. Precast wings and headwalls are prohibited at stream crossings. Cast-in-place end sections shall conform to KDOT Standard BR031.
For fill heights less than or equal to 3 feet: Use epoxy coated reinforcing steel and air entrained concrete Use a distribution slab meeting the requirements of KDOT Standard BR031. Use an approved “non-coal tar” bridge backwall protection system to cover the middle 1/3 of the top of precast arch culverts, the complete top slab of precast rigid frame culv erts and the uppermost 12 inches of the outside walls. Indicate on the shop drawings the limits of the bridge backwall protection system. Prior to beginning foundation construction, submit complete design calculations, including loadings, for the Engineer’s review. Design calculations and loadings may be submitted prior to the working drawing submittal. Submit design calculations sealed by a Kansas licensed Professional Engineer. Prior to fabrication, submit to the Engineer for review and approval, working drawings including the supplier’s manufacturing specifications, details of all phases of construction, including layout, joint details, lifting devices, casting methods, construction pl acement and details of any cast-in-place sections. Submit working drawings according to SECTION 105 . Designate proposed transportation methods, and submit over-height and overload permits, if required, with the working drawings. When required, submit falsework plans and calculations sealed by a Kansas licensed Professional Engineer according to SECTION 708 . PRECAST CULVERT LOAD RATING: Include a Load Rating Table on the working drawings and provide the SBO with a LFR and LRFR rating and support calculations for the structure. The load ra ting shall take into consideration varying fill depths and KDOT live load criteria. For LFR Load Rating, include HS-20-44, KDOT rating vehicles for Inventory and Operating rating factors. Rate the Heavy Equipment Tr ansport (HET) vehicle for Op erating rating factor. For LRFR, use HL-93 for Inventory and Operating. Submit a Load Rating Report along with the working drawings. Include in the Load Rating Report a summary rating table, assumptions used in the load rating, the depth of fill, material strengths and any other signif icant information required to load rate the precast culvert. The Load Rating will include all elements of the proposed system incl uding, but not limited to stub-walls and connections.
736.2MATERIALS
may require sampling, inspection or certification before use. Provide the Engineer samples of all materials requiring testing and approval, once the materials become available. Allow the Engineer free access to the manufacturing plant at all times for the purpose of inspecting materials, plant facilities and manufacturing and curing pr ocedures. Inform the Engineer of planned concrete 736 – PRECAST CULVERTS 700-130 placement and curing schedule before work is started. Use materials that comply with the applicable requirements:
Grade 4.0 and 4.0 (AE) Concrete ............................................................. SECTIONS 401 & 402* Aggregates for Not On Grade Concrete ................................................... SECTION 1102 Reinforcing Steel (Grade 60) .................................................................. DIVISION 1600 Reinforcing Steel (Epoxy Coated) (Grade 60) ......................................... DIVISION 1600 Welded Wire Fabric ................................................................................. DIVISION 1600 Bolts, Threaded Rods, Nuts ...................................................................... DIVISION 1600 Structural Steel ......................................................................................... DIVISION 1600 Joint Seals ................................................................................................. DIVISION 1500 Bridge Backwall Pr otection System ......................................................... DIVISION 1700 Geotextile Fabric ...................................................................................... DIVISION 1700 Aggregates fo r Back fill ............................................................................ DIVISION 1100 *For precast reinforced culverts constructed according to this specification, KT-73 testing is not required.
detailed working drawings. Longitudinal distribution reinfor cement may consist of welded wire fabric or deformed billet-steel bars. Welding is prohibited on reinforcing bars or wire fabric, except original welding required in manufacturing the wire fabric is acceptable.
Structural steel anchors and plates to meet design, geometric and construction requirements. AISI type 304 stainless steel expanded coil inserts for detached headwall connections. Use AISI type 304 stainless steel coil rods and nuts in headwall conn ections. Use either AISI type 304 stainless steel plate washers or AASHTO M 270 (ASTM A709) Grade 36 plate washers hot dip galvanized as per AASHTO M 111 (ASTM A123) in connections. Dowel Bar Splicer System satisfying load requirements and geometric constraints. Provide corrosion protection coatings for all bolts, threaded rods, nut, fasteners, etc. Hook Bolts in the attached head wall connections per ASTM A307. All hardware shall either be AISI type 304 stainless steel or ASTM A 123 galvanized.
with ASTM C877. The basis of acceptance for external sea ling bands will be a Type D Ce rtification as specified in
Documents.
paint or other approved means: Date of manufacture; Name or trademark, and location of the manufacturer; Mass of culvert section in tons; and The top of the section.
5, DIVISION 1100 .
Precast culvert units will be accepted on the basis of satisfactory results of material tests performed by the Engineer, compliance with dimensional requirements, and visual inspection at the point of usage.
736 – PRECAST CULVERTS 700-131 736.3 CONSTRUCTION REQUIREMENTS
installation or placement of the first 10 % of the structure sections and the in stallation or placement of the final 10% of the structure sections. Install according to the approved deta iled working drawings.
butyl rubber, rope-form joint sealant in the chamfer groove between all precast sections, prior to installing connection plates or hardware. Install a Type III external sealing band at each precast joint, or cast-in-p lace cold joint. Completely cover the surface area of closure joints and extend the sealing bands an additional 6 inches beyond the limits of closure joints. Overlap the bands to shed wa ter. Overlap the bands a minimum of 6 inches along the axis of the band; overlap the bands a minimum of 2 inches transverse to th e axis of the band. Place the bonding material to extend a minimum of 18 inches from the joint location. If geotextile is used to wrap the joint: Use only geotextile that has been properly stored. Store rolls in a manner which protects them from the elements. If stored outdoors, elevate and protect with a waterproof cover; Limit the exposure to the elements (between placement and covering) of the geotextile to a maximum of 7 calendar days; Do not drop any D 50 backfill larger than 6 inches onto the geotextile from a height greater than 1 foot; Do not drop any D 50 backfill smaller than 6 inches onto the geotextile from a height greater than 3 feet; and Do not contaminate the geotextile with grease, mud or other foreign substances. Replace contaminated or damaged geotextile. If approved by the Engineer, re pair damaged geotextile by placing a patch over the damaged area and sewing the patch to the geotextile. Extend the patch a minimum of 1 foot beyond the perimeter of the damaged area. Replace contaminated or damaged geotextile, or repair if approved, at the Contractor’s expense.
sections, wingwalls, end caps, headwalls and other concrete elements according to the Contract Documents. Use epoxy coated reinforcement for all closure joints when the f ill height, measured at the shoulder line, is less than or equal to 3 feet. Install pavement waterproofing membrane to extend 18 inches beyond the limits of all closure joint concrete or grout. This membrane is subsidiary to the culvert.
sides and top of the structure. When manufacturer’s recommendations require more granular material, install at no additional cost to KDOT.
procedures.
736.4MEASUREMENT AND PAYMENT
The Engineer will measure precas t arch culverts and precast rigid frame culverts by the linear foot. Precast and cast-in-place end caps, headwalls and wing walls are subsidiary to the culvert. When shown as a bid item in the contract, foundation stabil ization and concrete seal course will be measured and paid for according to SECTION 204 . When not shown as a bid item in the contract, foundation stabilization and concrete seal course are subsidiary to the culvert. Payment for "Precast Arch Culvert" and "Precast Rigid Fr ame Culvert" at the contra ct unit prices is full compensation for the specified work. The pavement waterproofing membrane is subsidiary to the culvert. The specified granular backfill is subsidiary to the culver t. Any additional granular backfill required by the manufacturer will be done at no additional cost to KDOT. 737 – CONTROLLED DEMOLITION
700-132SECTION 737
FIELD ERECTION
737.1DESCRIPTION
Evaluate project characteristics and develop unique Field Erection Plans for each qualifying structure within the Contract Documents acco rding to this specification. For the purposes of this specification, erection is th e process of transporting, handling and assembling the bridge components to result in a bridge structure that m eets all the geometric and structural requirements of the Contract Documents.
737.2ERECTION SUPERVISOR
The Erection Supervisor is the person responsible for all rigging and handling of bridge primary members. The Erection Supervisor shall be present at the erection site during the erecti on of all primary members of Category B & C Structures. All Erection Supervisors must be pre-qualified. To become pre-qualified, provide proof of experience that the Erection Supervisor has a minimum of 5 years experience and at least 10 projects similar in scope, type and complexity. KDOT will maintain a list of approved Erection Supervisors on a Pre-Qualified List. At the pre-construction meeting, submit to the KDOT Field Engineer proof of pre-qualification for the scope, type and complexity of the structure to be constructed.
737.3ERECTION PLANS
shop drawings according to SECTION 105 . KDOT will review the Erection Plan for all Categories, and either decline, or recommend for approval. The Engineer must approve the Erection Plan before work may begin. The level of review and the requirements for submittals by the Contractor to the Engineer are categorized by risk and complexity. FIGURE 737-1 defines the 3 categories for field erection. 737 – CONTROLLED DEMOLITION
Engineer. At a minimum, include the following: Shop details, camber diagrams, list of field bolts, and shipping statements showing a list of parts and their respective weights Proposed methods of erection A list of all equipment that will be used Crane pick locations and loads Falsework plans Temporary bracing requirements Blocking diagrams
Specific details for structural erection shall be clearly defined Spliced pieces Multiple girders Pick descriptions Bolting locations Number of fully tightened bolts at each splice Cross-frames or diaphragms Anchor bolts Temporary bracing FIGURE 737-1 Special Requirements for Bridge Designers to Designate Erectio n Plan Categories The initial Category is based on the chart which considers the length of the longest span, the curvature of the bridge and the skew angle. If skew is greater than 30°, move up one Category (A to B or B to C). If a structure crosses traffic or a railr oad, require Category B as a minimum. If the Contractor uses falsework bents or strong -backs for the field erecti on, Category C Erection Plans are required. The designer may elevate a structure to the necessary Category based upon engineering judgment and unique circumstances. 737 – CONTROLLED DEMOLITION 700-134 (2) Category B Erection Plan Requirements. Meet the Category A Field Erection Plan Requirements in subsection 737.3b.(1) above. In addition, submit the detailed Field Erection Plans according to SECTION 105 to the State Bridge Office (or Bureau of Local Projects) at least 4 weeks be fore beginning the erection process. List on the Field Erection Plans the Erection Supervisor that shall be present at the site during the erection of all primary members. Field Erection Plan development, authority, and responsibility fall under 3 separate Field Operations: Traffic Control (Field Operation One): This is site and structure specific control of tra ffic movements relative to the structural erection operations. This portion of the operation is developed by the Contractor’s personnel and will be reviewed and approved by KDOT’s Field Engineer. Field changes are under the auth ority of the Field Engineer.
Pick and Place (Field Operation Two): This includes crane movements, rigging operations, storage, assembling, loading and unloading operations of primary, secondary and falsework members. This includes placing the assemblies into the structure. This portion of the operation requires procedures, calculations and drawings and is developed by the Erection Supervisor. All field operations and field changes are under the authority, and the responsibility, of the Contractor’s Erection Supervisor.
Part of Permanent Structure (Field Operation Three) : Defined as the point in time when the primary member becomes part of the structure. When the primary member is released from the rigging or when it rests solely on the bridge bent, bearing device or falsework bent as a part of the uncompleted structure, the primary member is considered to be part of the Permanent Structure. This requires calculations, procedures and drawings to be developed and sealed by the Contractor’s Professional Engineer. Field changes must be approved and resealed by the Engineer who originally developed the plans before work begins. This work is under the authority of the Contractor’s Professional Engineer.
subsection 737.3b.(2) above. Additionally, there will be a pre-erection meeting before erection operations begin. The Erection Supervisor shall attend this pre-erection meeting to discuss any fi eld concerns related to the erection procedures and to increase famili arity with each structure site.
The calculations, as a minimum, shall include the following information: Calculations to substantiate structural adequacy and stability for each stage of erection, accounting for the structures lack of completeness or complex structural geometry. Calculations to determine translations and rotations at intermediate erection conditions. Design calculations indicating and verifying the load capacity, the stability of all temporary supports, falsework bents, and bracing when used to allow tr affic to travel under the incomplete structure. Calculations indicating structural redundancy of the incomplete structure shall be required at specific stages of erection. These calculations shall be required to account for unfo reseen obstacles to the erection process that necessitate haltinger ection at an undesignated stopping point.
737.4ERECTION INFORMATION
Submit a detailed Erection Procedure to th e Owner for each bridge structural unit. In the Procedure, address all requirements for erection of the structure in to the final designed configuration and satisfy all written Owner comments prior to the start of erection. As a mi nimum, include the following in the Erection Procedure: 737 – CONTROLLED DEMOLITION 700-135 a. The Contractor’s Engineers sha ll provide the following information: Plan of the work area showing pe rmanent support structures (piers and abutments), roads, railroad tracks, waterways (including navigational channe l), overhead and underground utilities and other information pertinent to erection. Erection sequence for all members noting any temporary support conditions, such as holding crane positions, temporary supports, falsewor k, etc. Member reference marks, when reflected on the erection plan, should be the same as used on shop detail drawings. In the Field Erection Plans, describe the number, location and bolting requirements for the permanent cross-frames or diaphragms for each stage of construction. In the Field Erection Plans, address the expected condition of each bearing device for each stage of construction. State the minimum number of positive bearing connections or su pplemental connections to each bent cap which will resist all potential destabilizing forces. In the Field Erection Plans, address traffic control and railroad issues. If falsework bents or strong-backs are used, the Fiel d Erection Plans shall meet falsework requirements as defined in SECTION 708 .
Location of each crane fo r primary picks showing all necessary information. Capacity chart for each crane configuration. Center of gravity, lift weight (including rigging) for all primary member picks. Primary member site delivery location and storage orientation. Details of any temporary lifting devices to be bolted/welded to or cast in to permanent members, including method and time (shop or field) of attachment, capacity and method, time and responsibility for removal. Temporary support details for bridge bearings.
Requirements for bracing. At the end of the workday, remove the members not properly braced in compliance with the Field Erection Plan from the bridge substructure elements. All rigging must have capacity stamps, tags or be otherwise permanently marked on the device (per OSHA Standards)
737.5CONSTRUCTION REQUIREMENTS
No erection work may begin without an approved Fiel d Erection Plan. The Contractor is responsible for the erection, even though the Field Erection Plans have been approved by the Engineer. See SECTION 105 . Keep the approved Field Erection Plans available on site at all times. Before erection begins, resolve any questions that any party may have. Prepare a Contingency Plan if the number of stable girder lines to be erected does not meet the Field Erection Plan number for a sequence proposed. (i.e. the plan says 6 girder lines and because of problems, 5 girder lines where erected before traffic delay penalties accrued). It is required that all traffic must be stopped wh ile overhead erection work involving the placement of primary members into the permanent structure is being performed. No members shall be suspended over highway traffic at any time during loading, unloading, moving, rigging or placing. In no case will KDOT allow highway/railroad traffic to travel under uncompleted structures without compliance of Fi eld Operation Three above. Erect the fabricated structure and perform all work requ ired to complete the structure as specified in the Contract Documents. Provide a ll falsework, tools, machinery and appliances required to complete the work. After the structure is erected, remove all falsework, appliances and other obstructions or debris resulting from erection. Provide the Engineer with safe means (such as scaf folding, safety lines, snoopers or hoist buckets) to inspect any portion of the structure during the erection operations. The Engineer will refuse permission to proceed with erection work if the erection process is determined to be unsafe or substantially different than approved Field Erection Plans.
737.6MEASUREMENT AND PAYMENT
Erection is considered complete when all field conn ections are completed to the final design condition and falsework is removed. The Engineer will not measure Fiel d Erection and Field Erection Plans for separate payment.