used during the operation. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS CATEGORY 400 STRUCTURES SECTION 479 — PRESSURE INJECTED EPOXY CRACK REPAIR
479.01 Description
Inject epoxy in cracks with a maximum width of 1/4 in.
479.02 Materials
The epoxy resin shall conform to 921.04, C 881, Type I. Submit the grade for approval after the Contractor’s analysis of the areas to be injected. The system shall be moisture insensitive and shall not be used when the ambient or concrete temperature is 50 F or below, nor temperatures lower than recommended by the manufacturer. The expiration date of acceptance of this material shall be one year after the date of manufacture. Any unauthorized tampering or breaking of the seals on the containers between the time of sampling and delivery to the job site will be cause for rejection of the material.
479.03 Construction
The locations for the pressure injection of cracks will be delineated by the Engineer. Ensure that the epoxy manufacturer’s technical representative will be present for the initial day of the epoxy injection process and submit details of the proposed method of repairs and the injection procedure for approval. Inject the epoxy with a positive displacement pump system having a suitable mixing chamber where the epoxy components are accurately metered and thoroughly mixed immediately prior to injection. A clear, legible, and accurate pressure gauge shall be located in the supply line adjacent to the mixing chamber. The equipment shall also be capable of providing a continuous and uninterrupted pressure head to continually force the injection of epoxy into the cracks. Epoxy flow shall be capable of being fully controlled by the operator controls at the mixing chamber. Ensure that all working personnel are familiar with the equipment, materials, and procedures to be All materials and equipment, including backup equipment, shall be at the work site before injection operations begin. All equipment shall be in proper calibration and in good working order as determined by the Engineer. Epoxy shall be injected only using the automatic mechanical pumping, metering, and mixing equipment described above. Pressure pot systems and caulking guns or grease guns will not be permitted. Mix the two components in accordance with the manufacturer’s recommendations. Maintain the ratio of the components within a tolerance of five percent. As a first order of work, clean the crack using a non-chlorinated, VOC compliant solvent that is approved by the epoxy manufacturer. Make sure the solvents have completely evaporated from the cracks or bonding surfaces prior to application of the surface seal or injection of epoxy.
479.03.01 Port Installation. Prior to injection of the epoxy in the crack, apply a surface seal
material to the face of the crack to prevent the liquid resin from leaking out. The surface seal material shall be usable on vertical, horizontal, and overhead applications and completely bridge the crack when applied to the face of the crack. Establish openings to inject the epoxy through the surface seal material along the entire length of the crack and provide entry ports. The holes shall be 3/4 in. in diameter, spaced 6 in. to 12 in. apart, and be of sufficient depth to ensure maximum dissemination of the pressure of the epoxy throughout this area. Set inserts in drilled holes that are cleaned to remove any dust or debris left by drilling operations. Exercise special care to ensure that oil or other contaminants are not introduced into the air feed hoses or deposited on any air blown surfaces.
479.03.02 Injection. Force the epoxy into the internal voids and cracks by means of hydraulic
pressure to completely fill all internal voids. If the surface seal material has insufficient strength and adhesion to confine the injected epoxy until it has cured, remove the surface seal material, and furnish and place a new surface seal material at no additional cost to the Administration. Before injecting any epoxy, activate the automatic mixing and metering pump and discharge approximately 1 pint of the mixed epoxy into a disposable container. The Engineer will observe this trial operation to determine that the equipment is working properly. If the equipment is not working properly, immediately repair it to full working condition or replace it with the backup equipment. If the backup equipment is used, additional and fully operable equipment shall be provided as backup equipment. Ensure that the feed line from the mixing equipment is securely held or properly attached to the port. Then initiate the epoxy injection in conformance with the manufacturer’s recommendations. Start the injection at the lowest row of holes and at the hole nearest the center line of the structure. Continue injection at the first port until the epoxy begins to flow out of the port at the next highest 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS unit price per quart for the pertinent Epoxy Used for Epoxy Pressure Injection item. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS elevation. Then plug the first port and start injection at the second port until the epoxy flows from the next port. Continue this sequence until the entire crack is repaired. Monitor the injection procedure to ensure the epoxy flow does not cease before the injection epoxy exudes from the adjacent port. If the epoxy flow stops before epoxy appears at the adjacent port, move the feed line to the adjacent port and seal the port just used. During the course of all operations, ensure extreme care to observe for breaking out of epoxy. When breaking out occurs, stop the injection, and move the line to another crack. Resume injecting in the original location after a minimum elapse of 24 hours. Accomplish a continuous injection operation by replenishing the epoxy supply tanks in the mixing equipment before they are exhausted. Thoroughly stir each epoxy component before adding it to its respective storage tank in the mixing equipment. No discontinuity of epoxy flow through the feed lines of either component shall be permitted. Any work stoppage permitting mixed epoxy to remain in the injection equipment more than 15 minutes requires cleaning the mixing chamber and all equipment in contact with the mixed epoxy. Quantities of epoxy purged from the injection equipment shall not be included for payment. After the injection process has been completed and the epoxy is allowed to fully cure, remove the injection ports, and surface seal from all surfaces. Cut or knock off ports and grind off the surface seal and any spillage flush with the original surface. Repair any damage to the concrete due to these operations in a manner satisfactory to the Engineer at no additional cost to the Administration. If the Engineer suspects that the epoxy is not completely filling the crack, they can request that the Contractor obtain 4 ins. diameter cores of the repaired concrete from representative locations selected by the Engineer. If the epoxy penetration depth is less than 90 percent of the visible crack along the sides of the core, the crack from which the core was taken will be deemed unsatisfactory and will not be included for payment. Fill the cored holes with epoxy grout.
479.04 Measurement and Payment
The preparation of cracks including chipping, cleaning, sealing, installation, and removal of injection ports, testing of repairs, repairing of cored holes, and for all material, labor, equipment, tools, and incidentals necessary to complete the item will be measured and paid for at the Contract unit price per linear foot for the pertinent Epoxy Pressure Injection item. The epoxy used shall not be included in this item but will be measured and paid for at the Contract 481 — REMOVING EXISTING BRIDGE SCUPPERS AND DOWNSPOUTS 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS CATEGORY 400 STRUCTURES SECTION 481 — REMOVING EXISTING BRIDGE SCUPPERS AND DOWNSPOUTS
481.01 Description
Remove existing bridge scuppers and fill downspouts where designated on the Plans.
481.02 Materials
Nonshrink Grout 902.11(c) PVC Pipe Section 905
481.03 Construction
Removing Existing Scuppers and Filling Downspouts. Completely remove all scuppers in conjunction with the removal of the existing bridge deck. Removal of the scuppers includes the grates, scupper basin, associated anchorages, and channels holding the scupper basin in place to the superstructure. Remove downspouts and piping connected to the removed scuppers in their entirety including all hangers, where designated in the plans. If the downspouts are designated in the plans to remain in place, fill the downspout piping with nonshrink grout.
481.04 Measurement and Payment
The payment will include scaffolding, removal of any debris in the scuppers, furnishing and placing nonshrink grout, and all materials, labor, equipment, tools, and incidentals necessary to complete the work.
481.04.01 Removing existing scuppers and filling the downspout piping with grout will not be
measured, but the cost will be incidental to the Removal of Portions of Existing Structure item.