2401Concrete Bridge Construction

2401.1DESCRIPTION

This Work consists of constructing portions of a Bridge made of concrete; except for concrete piling 2452, “Piling,” special wearing courses 2404, “Concrete Wearing Course for Bridges,” precast concrete members 2405, “Prestressed Concrete Beams,” and 2412, “Precast Concrete Box Culverts.” A Definitions For the purpose of the Work specified in section 2401, “Concrete Bridge Construction,” the Department defines: Bridge Deck Slab Complete Structural slab and wearing course constructed monolithically . Bridge Structural Slab Structural unit upon which will be constructed a separately cast concrete wearing course. Bridge Slab Either Bridge Deck Slab or Bridge Structural Slab. Well Lighted A minimum of 50 foot candles of artificial light or natural daylight. Use a light meter with readings in foot candles to verify the adequacy of the lighting.

2401.2MATERIALS

H Special Surface Finish Use only one Department-approved product to apply a concrete coating to the entire Structure that meets the need for aesthetics and chloride protection as listed on the APL , Bridge, “Special surface finish II coatings.” K High Performance Concrete Bridge Decks K.1 Concrete Aggregate Requirements Test each Aggregate fraction proposed for use in accordance with Table 2401.2-1.

Table 2401.2-1 Aggregate Testing Requirements Aggregate Fraction Testing Required Tested by Department in the last 3 years No additional testing unless required by the Concrete Engineer Not tested by the Department in the last 3 years Preliminary Aggregate testing in accordance with 2401.2K.1.a, “Required Preliminary Aggregate Testing” New source New source concrete Aggregate testing in accordance with 3126, “Fine Aggregate for Portland Cement Concrete,” 3131, “Intermediate Aggregate for Concrete,” and 3137, “Coarse Aggregate for Concrete”

K.1.a Required Preliminary Aggregate Testing After the Department awards the Contract and as soon as coarse and fine Aggregates are available for testing, contact the Engineer to coordinate preliminary sampling of Aggregate for concrete. The Engineer, in conjunction with the Concrete Engineer, will sample and test the Aggregate to verify specific gravity, absorption data, and Aggregate quality. The Department will perform other tests as determined necessary by the Engineer, in conjunction with the Concrete Engineer. K.2 Fine Aggregate Requirements Provide fine Aggregates complying with quality requirements of 3126.2B, “Quality.” The Department will routinely test fine Aggregate sources for alkali silica reactivity (ASR) in accordance with the following:

Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method), MnDOT Modified.

cementitious Materials in accordance with ASTM C1567, Standard Test Method for Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method), MnDOT Modified. The Concrete Engineer, in conjunction with the Engineer, will review the 14 Calendar Day fine Aggregate expansion test results to determine the acceptability of the proposed fine Aggregate and cement combination in accordance with the following:

Department, the Concrete Engineer will use the average of all 14 Calendar Day unmitigated test results for an individual source to determine necessary mitigation in accordance with Table 2401.2-2.

requires less mitigation than the average 14 Calendar Day unmitigated test result, the Concrete Engineer will allow mitigation at the lesser rate in accordance with Table 2401.2-2.

Alkali Reactivity of Aggregates (Mortar-Bar Method), MnDOT Modified and ASTM C1567, Standard Test Method for Determining the Potential Alkali -Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method), MnDOT Modified test results are available on the MnDOT Concrete Engineering Unit website. The Concrete Engineer considers the average 14 Calendar Day expansion result to represent all fine and intermediate Aggregates from a single source. Table 2401.2-2 Fine and Intermediate Aggregate ASR Mitigation Requirements 14 Calendar Day Fine and Intermediate Aggregate Unmitigated Expansion Limits Class F Fly Ash Class C Fly Ash Slag Ternary (Maximum of 40 percent) Slag/Class F Fly Ash Slag/Class C Fly Ash IS(20)/Class F Fly Ash IS(20)/Class C Fly Ash ≤ 0.150 No mitigation required > 0.150 – 0.200 Minimum 20 percent Minimum 20 percent 35 percent 20 percent Slag with a minimum of 15 percent Class F fly ash 20 percent Slag and 20 percent Class C fly ash Type IS(20) with a minimum of 15 percent Class F Type IS(20) with a minimum of 15 percent Class C > 0.200 – 0.300 Minimum 20 percent Minimum 30 percent 35 percent > 0.300 The Department will reject the fine Aggregate

The Concrete Engineer may reject the fine Aggregate if mortar bar specimens exhibit an indication of external or internal distress not represented by the expansion results. The Concrete Engineer will make the final acceptance of the Aggregate. K.3 Intermediate Aggregate Requirements Provide intermediate Aggregates complying with the quality requirements of 3131.2D, “Quality.” For any intermediate Aggregate size not previously tested by the Department, the Concrete Engineer reserves the right to test for alkali silica reactivity, in accordance with ASTM C1260, Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar -Bar Method), MnDOT Modified, prior to allowing incorporation into the concrete mix design. K.4 Coarse Aggregate Requirements Provide Class A, B, or C coarse Aggregate meeting the quality requirements in accordance with 3137.2D, “Quality,” for each individual fraction. When providing Class B Aggregate, the maximum absorption percent by weight is 1.10 percent.

K.4.a Coarse Aggregate Alkali Silica Reactivity (ASR) Requirements When using coarse Aggregate identified as quartzite or gneiss, the Concrete Engineer will review ASTM C1293, Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction testing to determine the necessary ASR mitigation requirements in accordance with Table 2401.2-3. ASR ASTM C1293, Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction test results are available on the MnDOT Concrete Engineering Unit website. Table 2401.2-3 Coarse Aggregate ASR Mitigation Requirements* ASTM C1293ǁ Expansion Results Class F Fly Ash Class C Fly Ash Slag Slag/Class F Fly Ash Slag/Class C Fly Ash IS(20)/Class F Fly Ash IS(20)/Class C Fly Ash ≤ 0.040 No mitigation required > 0.040 Minimum 30 percent Not Allowed 35 percent 20 percent Slag with a minimum of 15 percent Class F fly ash 20 percent Slag and 20 percent Class C fly ash Type IS(20) with a minimum of 15 percent Class F Type IS(20) with a minimum of 15 percent Class C * The Engineer will allow the Contractor to substitute a portion of the minimum required supplementary cementitious Material with up to 5 percent silica fume by weight for mitigation purposes. ǁ ASTM C1293, Standard Test Method for Determination of Length Change of Concrete Due to Alkali -Silica Reaction

K.5 Cementitious Materials Provide only cementitious Materials from the APL. K.5.a Portland Cement or Blended Portland Cement ............................. 3101 or 3103 Use Type I or Type I/II cement complying with total alkalis (Na2Oe) no greater than 3.0 pounds per cubic yard of concrete resulting from the Portland cement. Use Type IL, IS or IP cement complying with total alkalis (Na2Oe) no greater than 3.0 pounds per cubic yard of concrete resulting from the Portland cement content of the blend. The Concrete Engineer defines Class F fly ash for the purposes of ASR mitigation as having a maximum CaO content of 18.0 percent. K.5.d Silica Fume .................................................................................... ASTM C1240 K.5.e Ternary Mixes Ternary mixes are defined as Portland cement and two other supplementary cementitious Materials, or blended cement and one other supplementary cementitious Material with a maximum replacement of 40 percent by weight. K.6 Additional Ingredients Combine and blend as required.

K.6.a Allowable Admixtures Use any of the following admixtures on the APL, Concrete, “Admixtures:”

Obtain a written statement from the manufacturer of the admixtures verifying:

admixtures into the concrete The manufacturer will further designate a technical representative to di spense the admixture products. Utilize the technical representative in an advisory capacity and have them report to the Contractor any operations or procedures which are considered as detrimental to the integrity of the placement. Verify with the Engineer whether the manufacturer’s technical representative’s presence is required during the concrete placement. K.6.b Fiber Reinforcement ................................................................................... APL For bridge slabs, furnish one of the materials listed on the APL, Concrete “Non- metallic Fibers (Bridge Applications).” Provide fibers at a dosage as prescribed on the APL per the manufacturer. Incorporate the fibers into the mix design in accordance with the applicable requirements of 2401, “Concrete Bridge Construction,” and 2461, ”Structural Concrete.” K.7 Contractor Concrete Mix Design The Contractor assumes full responsibility for the concrete mix design and performance of the concrete. Acceptance of the concrete is contingent on meeting all specification requirements, including but not limited to requirements related to field placement and performance. K.7.a Concrete Mix Design Submittal Requirements Design and produce 3YHPC-M or 3YPHC-S concrete mixes based on an absolute volume of 27.00 cubic feet in accordance with the Table 2401.2-4.

Table 2401.2-4 High Performance Bridge Deck Concrete Mix Design Requirements Concrete Grade Mix Number* Intended Use W/C Ratio Target Air Content Maximum percent SCM (Fly Ash/Slag/ Silica Fume/ Ternary) ǁ Slump Range†, inches Minimum Compressive Strength, f’c (28 Calendar Day) 3137, “Coarse Aggregate for Concrete” HPC 3YHPC-M Bridge Deck – Monolithic 0.42- 0.45 6.5 percent 30/35/5/40 2 - 5 4000 psi 2D.2 3YHPC-S Bridge – Structural Slab * Provide a Job Mix Formula in accordance with 2401.2K.8, “Job Mix Formula.” Use any good standard practice to develop a job mix formula and gradation working range by using procedures such as but not limited to 8 -18, 8-20 gradation control, Shilstone process, FHWA 0.45 power chart, or any other performance related gradation control to produce a workable and pumpable concrete mixture meeting all the requirements of the Contract. ǁ The individual limits of each SCM shall apply to ternary mixtures. † Keep the consistency of the concrete uniform during entire placement. At least 21 Calendar Days before initial placement fo the concrete, submit the appropriate Project specific mix design to the Concrete Engineer for review. Use the most current forms, specific gravity, and absorption data available from the MnDOT Concrete Engineering website. Any changes or adjustments to the Material or mix design require a new Contractor mix design submittal. MnDOT will review the Contractor’s proposed mix design solely for compliance with the applicable mix design properties in Table 2401.2-4 and Table 2401.2-5. The Department makes no guaranty or warranty, either express or implied, that compliance with mix design properties ensures compliance with any other requirements . K.7.b Required Preliminary Testing Prior to placement of any 3YHPC-M or 3YHPC-S concrete, the Engineer will require preliminary batching and testing of the concrete mix design. The Concrete Engineer will not require new batching and testing for a period of 5 years from when the original concrete mix was tested as long as all the constituents (including the Aggregates) of the proposed mix design are the same as the original mix design . Test the concrete for the following hardened concrete properties in accordance with Table 2401.2-5.

Table 2401.2-5 Required Hardened Concrete Properties for Mixes 3YHPC-M and 3YHPC-S Test Requirement Test Method Required Strength (Average of 3 cylinders) 4000 psi at 28 Calendar Days ASTM C31* Rapid Chloride Permeability ≤ 2500 coulombs at 28 Calendar Days (for Preliminary Approval) ≤ 1500 coulombs at 56 Calendar Days ASTM C1202ǁ Freeze-Thaw Durability Greater than 90 percent at 300 cycles ASTM C666†, Procedure A Shrinkage No greater than 0.040 percent at 28 Calendar Days ASTM C157ǂ Scaling Visual rating not greater than 2 at 50 cycles ASTM C672# * ASTM C31, Standard Practice for Making and Curing Concrete Test Specimens in the Field ǁ ASTM C1202, Standard Test Method for Electrical Indication of Concrete's Ability to Resist ChlorideIon Penetration † ASTM C666, Standard Test Method for Resistance  of  Concrete  to  Rapid  Freezing and  Thawing ǂ ASTM C157, Standard Test Method for Length Change of Hardened Hydraulic - Cement Mortar and Concrete # ASTM 672, Standard Test Method for Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals

The Engineer will allow the maturity method for subsequent strength determination. Perform all maturity testing in accordance with ASTM C1074, Standard Practice for Estimating Concrete Strength by the Maturity Method, and the Concrete Manual. K.8 Job Mix Formula A job mix formula (JMF) contains the following:

each Sieve in accordance with Table 2401.2-6

Table 2401.2-6 Job Mix Formula Working Range Sieve Sizes Working Range, percent * 1 inch and larger ±5 3/4 inch ±5 1/2 inch ±5 3/8 inch ±5 No. 4 ±5 No. 8 ±4 No. 16 ±4 No. 30 ±4 No. 50 ±3 No. 100 ±2 No. 200 ≤ 1.6 * Working range limits of the composite gradation based on a moving average of 4 tests (N=4). K.8.a Verification of JMF Prior to beginning placements of Bridge deck concrete, perform gradation testing to ensure current Materials comply with the approved JMF. Perform gradation testing in accordance with the Schedule of Materials Control.

locations close to the incorporation of the Work as approved by the Engineer

overloading The Producer and Engineer will test and record the individual gradation results using the Concrete Aggregate Worksheet. Using the JMF Moving Average Summary worksheet, calculate the moving average of Producer Aggregate gradation test results during production. The Engineer will randomly verify Producer combined Aggregate gradation results as defined in the Schedule of Materials Control. If, during production, the approved JMF falls outside of the allowable working range immediately sample and test additional gradation and continue production. K.8.b JMF Adjustment If it is determined that the current Aggregates do not meet the approved JMF, submit a new mix design including JMF to the Concrete Engineer in accordance with 2401.2K.8, “Job Mix Formula.” K.9 Laboratory Batching, Testing Requirements and Submittals To determine the characteristics of the Contractor proposed mix design, the Concrete Engineer will require the Contractor to prepare test batches and do laboratory testing. Conduct all batching and testing of concrete at a single AASHTO accredited laboratory using the exact Materials proposed in the mix design.

Lab testing requirements:

completion of mixing

Standard Method of Test for Making and Curing Concrete Test Specimens in the Laboratory, and tested in accordance with AASHTO T22 Standard Method of Test for Compressive Strength of Cylindrical Concrete Specimens ) at 1, 3, 7, 28, 56 Calendar Days (sets of 3)

Determination of Parameters of the Air-Void System in Hardened Concrete) at a minimum of 7 Calendar Days

Indication of Concrete's Ability to Resist ChlorideIon Penetration) at 28 Calendar Days and 56 Calendar Days (2 specimens for 28 Calendar Day test and 2 test specimens for 56 Calendar Day test (Take 2 specimens from each batch of a 2 batch mix))

of Concrete to Rapid Freezing and Thawing, Procedure A) at 300 cycles

Hardened Hydraulic-Cement Mortar and Concrete) at 28 Calendar Days

Concrete Surfaces Exposed to Deicing Chemicals) at 50 cycles The Contractor is required to contact the MnDOT Concrete Engineering Unit a minimum of 2 Calendar Days prior to any mixing so that a MnDOT representative can observe the process. This same Calendar Day notification is required prior to any physical testing on hardened concrete samples. Additionally, retain any hardened concrete test specimens for a minimum of 90 Calendar Days and make available for Department to examine. Perform all testing for plastic concrete after all admixtures additions to the concrete mixture. After completion of the laboratory testing specified herein and, at least, 15 W orking Days prior to the trial placement, submit the laboratory test data to the Department for review and acceptance. Include the following information in the laboratory reports of the design mixes:

gradations

Day (sets of 3)

design

2401.3CONSTRUCTION REQUIREMENTS

A General Refer to 2402, “Steel Bridge Construction,” 2404, “Concrete Wearing Course for Bridges,” 2451, “Structure Excavations and Backfills,” 2452, “Piling,” 2471, “Structural Metals,” and 2472, “Metal Reinforcement,” for constructing Bridges. B Falsework and Forms Use forms for concrete except portions of footings that extend into solid rock . Do not cast concrete against the side of an earth excavation instead of forming. If the Special Provisions allow driving the sheets along the neat line of a footing, the Contractor may use cofferdam sheets as forms for footings. B.1 Material Requirements, with Allowable Stresses or Loads B.1.a Falsework Piling Calculate safe pile-bearing capacities in accordance with 2452, “Piling.” B.1.b Structural Shapes and Fabricated Assemblies Reduce the safe load capacity for Material or fabricated assembly that has a loss of section due to corrosion, damage, or previous fabrication . Splices in beams or girders must be at points of one-half maximum bending stress or less. Splices shall develop yield on the gross section and fracture on the net section. Design trusses, other fabricated sections, and steel beams to meet the requirements of the AASHTO Guide Design Specifications for Bridge Temporary Works and the AASHTO Standard Specifications for Highway Bridges. The Contractor may increase the allowable stresses in the AASHTO Standard Specifications for Highway Bridges by no greater than one-third. Design and use form ties and other steel devices planned for casting into concrete so that the major part, or the entire device, remains permanently in the concrete. If using a device that passes through a concrete surface exposed to view in the completed Structure, use a device removable to a depth of at least 1 inch from the concrete face without spalling or damaging the concrete. B.1.c Lumber Provide lumber free of defects that may adversely affect its strength or the appearance of exposed concrete lines and surfaces, such as crooks, twists, warps, and variations in dimensions. Surface the side of lumber pieces that will contact concrete. If not using form lining, surface or dress and match abutting edges to prevent mortar leakage. Working stresses for lumber shall not exceed the maximum stresses specified in the Bridge Construction Manual, Falsework and Forms section. Provide sheathing lumber, either with or without form lining, at least 1 inch Nominal thickness and no greater than 8 inches wide for exposed concrete surfaces. If a single piece of lumber will completely cover a concrete surface and the lumber is not cupped or warped, the Contractor may use wider lumber. For curved surfaces with a radius of less than 5 feet, the Contractor may use sheathing thinner than 1 inch Nominal as long as the sheathing maintains its shape during concrete placement.

B.1.d Plywood Sheathing Provide plywood for form sheathing meeting the following requirements and characteristics:

manufactured for use as form sheathing

Falsework and Forms section The Contractor may use the plywood without backing if it meets the above requirements. For curved surfaces with a radius of less than 5 feet and for slab sections between girders or beams, the Contractor may provide plywood sheathing thinner than 3/4 inch Nominal, as long as the sheathing maintains its shape during concrete placement. B.1.e Form Lining If the Contract requires form lining, use plywood sheathing with a smooth surfaced Material that will produce a concrete surface substantially as smooth and uniform as that obtained using sanded or overlaid plywood sheathing in good condition with no warps or damaged areas. Use the same kind of form lining Material throughout an exposed concrete face. Place the form lining to produce a smooth contact surface that is free of defects. Provide smooth form lining free of defects that cause irregularities that the specified concrete finishing operations in 2401.3F, “Finish of Concrete,” cannot remove. Provide form lining Material with a uniform thickness and edges that form mortar tight joints. Ensure that bolt, nail, or rivet heads and weld deposits are flush with the form lining face in contact with concrete. If using form lining sheets or sections, use Material that minimizes the number of joints. B.1.f Forms for Circular Columns Use forms that can withstand design concrete pressures without distortion. Use forms to produce a concrete surface free of visible ridges and depressions . If form lining is shown on the Plans, the Contractor may use fiber molds. When using form brands not previously used, provide the Engineer with the manufacturer’s data. B.1.g Chamfer Strips Provide smooth chamfer strips uniform in cross-section dimensions without rounded corners. If using wood strips, provide wood strips made of straight grain soft wood. Size chamfer strips as shown on the Plans and in accordance with 2401.3B.6, “Form Construction.” B.2 Design of Falsework and Forms Submit detailed Plans for falsework and forms to the Engineer. Submit design calculations for falsework if included in special provisions or if requested by the Engineer.

B.2.a Falsework Provide falsework members designed to safely carry the following forces:

foot

concrete surface

the members

during construction B.2.b Forms Provide forms designed to safely carry the following forces:

cubic foot

concrete surface

during construction Consider the specified live load as the minimum. Adjust for concentrated loads that may produce higher live loads on a member than the minimums specified. B.2.c Falsework and Forms Provide falsework and forms designed in accordance with the following as specified in the Bridge Construction Manual, Falsework and Forms section:

Provide credible information regarding the performance of the proposed falsework and forms under concrete load construction for any type of construction not included in the Bridge Construction Manual, Falsework and Forms section, as requested by the Engineer. Before using devices or fabrications that the Engineer determines the Department does not have sufficient performance information on, conduct full scale field or laboratory testing of falsework and forms at no additional cost to the Department.

B.2.d Forming Systems Relying on Prestressed Concrete Beams Lateral and rotational stability of the prestressed concrete beams during handling, transporting, erection and deck placement is the responsibility of the contractor. The evaluation may include the permanent diaphragms, if provided in the plans, and any temporary diaphragms if additional restraint is needed to resist the forces from the concrete, forms, equipment, workers, wind, and any other construction loads present. Special consideration by the contractor will be needed for deck finishing machines supported on the outside of the deck. All costs associated with the evaluation and temporary restraint if needed is the responsibility of contractor B.3 Form Lining Requirements Nail form lining backed by sheathing to prevent bulging. Fasten plywood at least 3/4 inch thick to its supports to ensure stiffness and close contact between the plywood and supports. Tightly butt edges of plywood sheets and form panels without offset to form a mortar tight joint. The Engineer will allow the Contractor to patch or seal joints that will not seal with cold water putty, expandable foam, or an equivalent. Place joints in form lining sections or between adjacent form panels following the same horizontal line. Place horizontal joints on columns of a unit to the same level. Align joints in form lining vertically and horizontally. On forms for concrete faces exposed to view, drill holes for form bolts through sheathing or form lining without splintering the face of the form in contact with the concrete . If using both sides of sheathing, avoid splintering on both faces. Use form lining in accordance with 2401.3B.1.e, “Form Lining,” for formed surfaces. The Department will not require use of form lining for buried surfaces or surfaces hidden from view in the completed Structure, except as shown on the Plans. If using recessed rustication strips to divide a concrete surface into panels as shown on the Plans, set rustications to cover the joints in the form lining. Concrete panels with a rubbed surface finish or a special surface finish do not require form lining joints to be covered by rustication strips. B.4 Falsework Requirements Support falsework on piling, on ledge rock, on parts of the S tructure, or on temporary footings. Do not weld on stress-carrying steel members of the Bridge Superstructure except as specified in 2402, “Steel Bridge Construction.” Welded or bolted splices in main load carrying steel members shall meet the requirements of 2402, “Steel Bridge Construction,” and 2471, “Structural Metals.” Drive falsework piling to a bearing capacity and penetration that will adequately support the superimposed loads without settlement as shown in the falsework Plans. Use temporary footings to support falsework in accordance with the following:

bearing capacity, anticipated settlement, and sliding resistance, for proposed footings showing that detrimental settlement will not occur under maximum construction loads and conditions anticipated at the site.

bearing pressure.

Cut off falsework piling in a bent to provide uniform bearing for the pile cap. Securely fasten caps to the pile heads or posts. Securely brace each falsework bent with timber or steel of adequate size as shown on the falsework Plans. Securely brace the bents to adjacent bents. Provide falsework for Superstructures in widths greater than the overall width of the Superstructure to brace side forms to the falsework. On Bridges with separate Roadways, support the form and falsework supports for each Roadway slab with beams or girders under that Roadway. Locate primary supports for concrete slab spans and the bottom slab for concrete box girders no greater than 2 feet from the construction joints in the slabs. Provide falsework for slab overhangs for steel beam spans capable of resisting torsional stresses. Use knee bracing, cross bracing, struts, ties, or other methods approved by the Engineer to prevent pronounced deflections caused by stresses. Bracing is particularly critical when slab overhangs are greater than the beam depth. B.5 Removal of Falsework Do not release falsework supporting concrete Structures and concrete members until the completion of the curing period in accordance with 2401.3G, “Concrete Curing and Protection,” plus one Calendar Day of drying out time. Release falsework supporting post tensioned structures after stressing the post tensioning tendons as described in the Specifications and shown on the Plans. Do not place loads beyond those included in 2401.3G.6.e, “Protection from Premature Loading,” on concrete members until completion of curing and after the release of falsework, unless otherwise approved by the Engineer. Determine adequate strength for the complete Structure using the last concrete cast affected by the release of falsework. Loosen supporting falsework to allow the concrete to uniformly and gradually take the stresses due to its own weight. Do not apply live loads to the Superstructure at any point while falsework is partially loosened on any part of the Bridge. Remove falsework piles located within the Roadbed to an elevation of at least 4 feet below the Subgrade adjacent to the pile. Remove falsework piles located in a stream or lake bed and within the limits of low water to the elevation matching the surface of the stream or lake bed. In established navigation channels, remove falsework to an elevation of at least 2 feet below the surface of the channel bottom. Remove all other piles to an elevation of at least 2 feet below ground elevation. Remove falsework supports used for the top slab of concrete box girder spans and steel box girder spans. Remove temporary footings.

Backfill and compact open excavations resulting from the removal of falsework in accordance with 2451, “Structure Excavations and Backfills,” at no additional cost to the Department. B.6 Form Construction Provide forms meeting the following requirements and characteristics:

vibration and of other loads Incidental to the construction operations

the dimensions and contours shown on the Plans, and so that undulations and waves on exposed finished concrete surfaces do not exceed the maximum shown in the Bridge Construction Manual, Falsework and Form section

removal of forms per 2401.3B.8, “Removal of Forms” For vertical construction joints in a concrete unit with a rubbed surface finish, locate joints in form sections to allow the removal of the major part of the forms to allow the initial rubbed surface finish on the cast portion. Construct vertical forms that will permit removal independent from overhead falsework. Place sheathing lumber horizontally unless otherwise approved by the Engineer. Construct splices in wales so the wale remains effective continuously for its entire length. Stagger splices in each member of a double wale at least one stud space. The Contractor may leave openings in the forms to clean out extraneous matter or to facilitate the placement of concrete if the Engineer approves the number and location of openings. Construct closures for openings to ensure a tight fit flush with the adjoining surfaces. Unless the Plans show otherwise, use chamfer strips with 3/4 inch sides to form chamfered corners where exposed intersecting concrete surfaces meet at angles no greater than 90 degrees. The Department will not require chamfered corners at the corners of beam stools under decks with mortar tight joints. If the Contract does not require joint edging, use similar moldings with 1/2 inch sides at joints exposed to view. Fasten moldings at intervals no greater than 6 inches. Set chamfer strips at the tops of pier caps supported on falsework in a manner that will allow adjustment to true Bridge seat elevation after the placement of the bulk of the cap concrete. The Contractor may provide forms for keyways at construction joints in concrete constructed with Nominal lumber dimensions and with side bevels no greater than 1:10. Provide forms for open joints capable of removal without damaging the joint after the removal of the form. Before setting grade elevations for curbs, Sidewalks, medians, and railings, free the concrete box girder spans and concrete slab spans from temporary supports. Do not drive nails into the hardened concrete to fasten forms for Roadway faces of curbs, Sidewalks, and medians. Use braces and struts to maintain proper line and batter for Roadway curb face, Sidewalk, and median forms, if these are cast separately from the slab . Do

not use internal spreaders. Do not install bolts and pins set or drill into the slab for the formwork more than 1 1/2 inches below the slab surface. Install all hardware into the slab surface without spalling or damaging the concrete. Remove all hardware from slab and fill the holes flush with non-shrink grout listed on the APL, Concrete, “Packaged, dry, non-shrink, rapid-hardening cementitious materials for concrete repairs.” If constructing a Bridge with a horizontal curve as shown on the Plans, construct the forms for edges of slab, curbs, copings, medians, and railings to that degree of curvature within a tolerance of 1/8 inch in 10 feet. B.7 Treatment of Forms Before placing reinforcement, treat the contact faces of forms with a form coating material in accordance with 3902, “Form Coating Material.” Apply the form coating at the rate recommended by the manufacturer. Protect form lining treated before erection from accumulations of dust and dirt. Use water to wet faces of forms that contact concrete immediately before placement of concrete. B.8 Removal of Forms Do not remove forms until provisions are in place for continuous curing in accordance with 2401.3G, “Concrete Curing and Protection.” Remove forms and form ties carefully to prevent spalling or marring of the concrete surface and to avoid breaking off concrete corners. The Contractor may remove forms for the Roadway face of curbs, Sidewalks, and medians when the concrete can retain its shape and if weather conditions allow the start of the specified concrete finish per 2401.3F.2.d, “Curb, Sidewalk, and Median Finish,” immediately after removing the forms. Remove column and wall forms before releasing the falsework supports from concrete supported by the column or wall. Do not remove forms for rustication, fluting strips, and drain recesses at the same time as the face forms. Leave rustication, fluting strips, and drain recesses forms in place until it is possible to remove these items without spalling, chipping, or marring of concrete corners or edges. Remove forms for the webs of concrete box girder spans and provide the web concrete with an ordinary surface finish before setting the forms for the top slab in place at that location. Remove interior forms in concrete box girder spans. Remove deck forms on the interior of steel box girder spans. Clear loose Material from the inside of the concrete box girders and steel box girders, and sweep the box clean. B.9 Reuse of Forms The Contractor may reuse forms and form liners if they are sufficiently rigid so that the undulation of the concrete surface does not exceed 1/8 inch when checked with a 5.0 foot straightedge or template. If the form lining between supports show conspicuous permanent set, remove the form lining and correct before reuse.

Plug or cover open holes in sheathing. Plug open holes in form lining flush with the lining. Repair blemishes on the form lining surface to a smooth and even surface. Clean adhering concrete and extraneous matter from form surfaces in contact with concrete before reuse. C Placement of Concrete – General Requirements Complete the placement of forms, falsework, bracing, and reinforcement bars for the entire concrete cast and have concrete placement and finishing Equipment and curing Material on site before placing the concrete. Notify the Engineer at least 24 hours in advance of the casting of concrete to allow the Engineer to inspect forms, reinforcement bars, Materials, and Equipment. Do not place concrete until the Engineer inspects and approves the Work. Perform mixing, placing, and finishing of concrete under adequate lighting conditions. Transport and place concrete without segregating the batch Materials. Place concrete in or near its final position without displacing the reinforcement while completely enveloping the reinforcement in the concrete. Keep Equipment for transporting, placing, and finishing concrete free of foreign matter and coatings of hardened concrete. Waste the water used for cleaning Equipment outside of the forms per environmental regulations and Specifications. Clean forms and reinforcement bars and remove debris inside the forms before placing concrete. Place concrete under water only when used for a cofferdam seal and as shown in the Special Provisions. When placing concrete on or against earth and porous rock foundations, moisten the surfaces before placing concrete. Footings cast in solid rock will not require side forms. Place concrete between required or permissible joints as shown on the P lans in a continuous operation. If a breakdown in the concrete placement operation occurs and the concrete placed to that point sets so that re-vibration is not possible, cover the surface of the concrete with an approved bonding agent or mortar, or install a construction joint, as accepted by the Engineer before placing fresh concrete against it. Place concrete at a rate that does not exceed fluid pressure for which forms were designed . Stop casting operations at signs of overstress or excessive deflection. Except for seals, deposit and compact concrete in continuous horizontal L ayers no greater than 1 foot thick. In columns and thin walls, the Contractor may increase the thickness to no greater than 3 feet. Place and compact concrete before the concrete in the preceding L ayer takes its initial set. Place Layers of concrete within 1 hour of placing the next Layer of concrete at the same point, unless otherwise approved by the Engineer. Do not drop concrete from a height greater than 4 feet unless confined in a vertical down spout or other approved type of pipe or unless the Engineer approves another placement method. Use as many down spouts as needed to place concrete at a horizontal level. The Contractor may use inclined pipes, belts, or chutes to discharge concrete into the hopper of the downspout if the Contractor provides approved means of preventing segregation.

Place concrete buckets as close as practical to the point of deposit before discharging concrete . Discharge concrete at a rate that does not displace reinforcement bars, forms, supports or any embedded items. Do not discharge excess concrete in a pile for re-handling. Remove laitance and foreign matter if it accumulates on the inside of the forms. Do not mix dried or hardened concrete accumulations with fresh concrete. As the concrete rises in the forms, keep the form surfaces and reinforcement bars free of concrete spatters that may harden and become part of the mix. Remove dried concrete and dust accumulations on the form surfaces and reinforcement bars above construction joints before placing the next concrete L ift. Do not damage the form surfaces, reinforcement bar coating, or the steel-to-concrete bond when removing excess concrete. Work the coarse Aggregate away from the forms. Force the concrete under and around the reinforcement bars without displacing the bars. If casting a wall or column greater than 5 feet tall integrally with a beam, strut, or slab, allow from 30 minutes to 90 minutes, as determined by the Engineer, to elapse between placement of the concrete to the level of the bottom of the beam, strut, or slab and placement of the concrete above this level. For caps supported by more than one column, cast columns uniformly and allow from 30 minutes to 90 minutes to elapse, as determined by the Engineer, before placing the cap. Clean set concrete of loose Material, laitance, and dirt before placing fresh concrete against it . Sand or water blast Superstructure concrete to clean the set concrete. Avoid damage to coating on reinforcement bars. Before placing the fresh concrete, draw the forms for the fresh concrete tight against the set concrete. Keep the contact surfaces of the set concrete wet until depositing the fresh concrete. If the Engineer determines that shock waves from pile driving, blasting, or other operations will damage the concrete, complete these operations before placing concrete or suspend these operations until the concrete gains adequate strength per 2401.3G, “Concrete Curing and Protection.” Do not support runways for concrete transportation by the forms unless approved by the Engineer. Remove the span falsework and obtain an acceptable Bridge Slab cure before placing concrete barriers. D Compaction of Concrete Compact concrete, except for cofferdam seals, using mechanical vibration applied internally . Operate vibrators at a frequency of at least 4,500 impulses per minute. Compact each batch of concrete immediately after placement. Apply vibrators at points no farther apart than twice the radius of the vibrator’s visibly effective range. Manipulate the vibrators to Work the concrete around reinforcement and imbedded fixtures and into the corners and angles of the forms. Use spading to supplement vibration to produce smooth surfaces and dense concrete along form surfaces and in corners and locations unreachable by vibrators. Apply vibration at the point of deposit of freshly deposited concrete . Vibrate long enough to compact the concrete but not so long as to cause segregation and localized areas of grout . Insert and withdraw vibrators in a vertical orientation. Extend vibrators into previously placed concrete of columns, web walls, or other multiple Layer placements.

Do not apply vibration to, or apply vibration directly on reinforcement bars to sections of concrete that has hardened to the degree that the concrete ceases to be plastic under vibration. Do not use vibrators to make concrete flow in the forms; this action will cause segregation. Use non-metallic vibrator head for compaction of concrete around epoxy -coated components per 2472.3C.3, “Special Requirements for Coated Bars.” E Joint Construction Perform joint construction as shown on the Plans and in accordance with the following: E.1 Transverse Construction Joints Immediately prior to placing concrete against a construction joint in the bridge slab, coat the surface of the inplace concrete with an approved bonding grout per 2404.2B, “Bonding Grout” E.2 Weakened Plane Joints Use a grooving tool or a removable insert when casting the slab to extend and form a weakened plane under Sidewalks and at other slab locations where a saw cut is not possible. Place the insert or groove to cut the fresh concrete on a straight line to a depth of 1 inch. When using an insert, coat with oil or grease before placement. Withdraw the insert when the concrete has set enough to retain the groove shape with the insert removed. Locate the weakened plane to fall vertically below the Sidewalk, curb, or median joint at that location. On skewed Bridges with exterior girders or beams under curbs, Sidewalks, or medians that are normal to the longitudinal axis of the Bridge, extend the weakened plane using a removable insert. Place the insert as a continuation of the line to be cut, extending to the centerline of the exterior girders or beams. Outward from the centerline of the exterior girders or beams, place the weakened plane common to the joint placed in the curb, Sidewalk, or median. Form a vertical 1/2 inch V-shape in the edge of the slab at the end of the weakened plane at that location. E.3 Open or Filled Joints Form the distance between faces of open joints with removable inserts, headers, or templates to provide the opening shown on the Plans for the temperature range prevailing at the time of concrete placement. Refer to the tabulation shown on the Plans or shop drawings for the required openings at various temperatures. The temperatures listed represent the temperature anticipated when the slab is cast. Joints may widen due to concrete shrinkage. After placing the Bridge Slab adjacent to an elastomeric seal expansion joint, and after curing and drying the concrete, the Engineer will measure the constructed joint openings . The Engineer may reject openings that deviate from the size shown on the P lans by greater than 3/16 inch as unacceptable Work in accordance with 1512, “Unacceptable and Unauthorized Work.” The Department will also consider offsets at joints between segments as unacceptable Work. The Contractor may use preformed joint filler to form vertical joints. When using cork joint filler to form a vertical joint, anchor with copper nails 2 1/2 inches long at 20 inch centers. Where the Contract requires chamfered corners at joints created by using preformed material, trim the preformed filler back to the inside of the vee formed by the chamfer strip. E.4 Expansion Joint Devices Provide, assemble, and install Bridge Slab expansion joint devices as shown on the Plans and in accordance with 2473, “Expansion Joint Devices.”

F Finish of Concrete F.1 General Surface finish concrete that is properly set, and only during weather conditions, or with weather protection, accepted by the Engineer. F.2 Formed Surfaces F.2.a Ordinary Surface Finish Provide ordinary surface finish on formed surfaces of concrete Structures. If applying special surface finishes to conventionally formed concrete surfaces, sand or water blast the surface before ordinary surface finishing to break the surface film and to remove laitance, form release agent, dirt, and other foreign matter that mig ht adversely affect adhesion of special surface finishes. Immediately after removing the forms, examine the concrete surfaces for defects. Remove and repair concrete with porosity, honey comb, or segregated Materials. The Engineer will approve the time, method, and Materials used to make concrete repairs. Repair small areas with mortar as specified for surface cavities . The Engineer may require formed surfaces to repair large areas. The repairs may require a bonding agent, mechanical bonds, or both. Cure repair work as approved by the Engineer. The Engineer may reject concrete sections with extensive, irreparable defects as unacceptable Work in accordance with 1512, “Unacceptable and Unauthorized Work.” Remove fins and projections from exposed surfaces and from surfaces that will be waterproofed. Clean, saturate with water, and fill with mortar surface cavities produced by form ties. Clean, saturate with water, and fill with mortar surface cavities on exposed surfaces with a diameter of at least 3/8 inch. The Department defines “exposed surfaces,” as surfaces exposed to view in the completed Structure, above low water, and above the final ground line. At unexposed surface locations or areas where the Engineer determines repairs will not affect the appearance of the completed Structure, clean and fill cavities caused by removing falsework, brackets, form ties, or hanger rods with a silicone caulk listed on the APL, Bridge, “Bridge silicone joint sealants.” Use mortar consisting of three parts standard Portland cement, six parts mortar sand, and water to fill surface cavities. Use enough water to produce a mortar consistency as dry as possible to use effectively. Mix the mortar 1 hour before use. Provide a latex or acrylic-based bonding agent listed on the APL, Bridge, “Special surface finish.” Mix the bonding agent into the mortar used for ordinary surface finishing on areas that will receive a special surface finish. Add the bonding agent to the mixing water at a ratio of one part bonding agent to three parts water. Fill the cavities with mortar. Compact the cavities in place, point, and trim flush with the concrete surface. On exposed surfaces, remove mortar stains or streaks outside the area of the filled cavity. After completing the concrete Work, remove visible streaks, stains, and blemishes from the surface if the Special Provisions do not show additional surface finishing on an exposed surface. Perform additional surface finishing on an exposed surface for which the Contract that requires only ordinary surface finish when adjoining

form lining sheets present sharply contrasting colors or textures . Provide sack rubbed surface finish as a corrective measure if the surface appearance remains sharply contrasting after the completion of the ordinary surface finish. If applying the ordinary surface finish before the completion of the curing period, minimize interruption to the curing when performing the finishing. F.2.b Sack Rubbed Surface Finish In areas with numerous surface voids on an exposed surface, the Contractor may use sack rubbed finish to fill the smaller voids in lieu of the method described under ordinary surface finish. Fill form tie holes and other cavities of at least 3/8 inch in accordance with 2401.3F.2.a, “Ordinary Surface Finish.” Grind or sandblast the concrete surface to remove blemishes, discolorations, and thin mortar films covering surface voids. After the completion of the Structure, and when further construction will not produce blemishes and discolorations on the surface, perform the following operations:

rubber float to apply a mortar mixture to fill the voids. Mix the mortar using the following requirements:

that will remain in place when applied; rewet the concrete surface if it dries before applying the mortar paste

the floated surface using a burlap sack filled with a dry mix of mortar to remove mortar in excess of what was needed to fill the voids. The Engineer will accept equally effective means of removing the excess mortar.

characteristics:

in texture between filled voids and the remainder of the surface Correct surfaces not meeting the requirements of this section. F.2.c Special Surface Finish This Work consists of the preparation of the concrete surfaces, cleaning the surfaces, furnishing and applying a single component Special Surface Finish II (SSF II) finish on Structure surfaces required by the Contract. Submit and follow the approved Quality Control Plan to produce a surface uniform in texture and appearance. Final approval of appearance will be made by the Engineer.

Use only one Department-approved product to apply a concrete coating to the entire Structure that meets the need for aesthetics and chloride protection as listed on the APL, Bridge, “Special surface finish II coatings.” Supply a SSF II product that meets the requirements of 3501, “Basic Requirements for Paints.” Provide a color drawdown sample on a Leneta chart per ASTM D2805, Standard Test Method for Hiding Power of Paints by Reflectometry, to the Engineer. The Engineer will provide the drawdown sample to the Materials Engineer for color verification prior to the SSF II being applied. The Department requires an acceptable initial drawdown sample prior to beginning any W ork because color testing is the initial control for the quality of the product. The Engineer will randomly take liquid samples of SSF II in the field at the rates and sample sizes that are shown in the Schedule of Materials Control. The Engineer will provide the samples to the Materials Engineer for drawdown readings. The Engineer will sample an entire unopened, manufacturer sealed container if the Engineer determines there is a need. Deliver SSF II product to the job site in manufacturer sealed containers bearing the manufacturer’s original labels. Assure SSF II containers remain sealed and are maintained at a temperature above 40°F and less than 100°F and not in direct sunlight until ready to be mixed and sampled. Do not use product that is older than its shelf -life. F.2.c(1) Contractor Qualifications and Documentation At least 20 Calendar Days before starting SSF II application submit a Project specific Quality Control Plan (QCP) meeting the requirements of Table 2401.3-1 to the Engineer for acceptance. In appendices of the QCP include:

SSF II manufacturer's technical representative trained the applicators

SSF II coating system used on this Project

and document the wet film measurements taken to assure proper coating mils are being maintained utilizing ASTM D4414, Standard Practice for Measurement of Wet Film Thickness by Notch Gages

letter accepting the initial color The Department’s Quality Assurance Inspector (QAI) will take wet- film readings and review Contractor QCP documentation as necessary to assure the Contractor is in compliance with the Specifications. Supply wet film notched gauges to the QAI as needed. Provide written documentation of the observed and document results of the requirements in Table 2401.3-1 to the QAI or to the Engineer within 5 Working Days from when each SSF II application shift was completed and all testing results in their entirety at the completion of the job. All SSF II QCP results are required to be submitted to the Engineer, prior to receiving either partial or full payment for SSF II application. The QAI or the Engineer will

reject the coating system or reduce payment if the Contractor did not adhere to the QCP or provided inadequate documentation of adherence to the QCP. Table 2401.3-1 Concrete Coating Inspection Requirements Requirements Frequency/Extent General Date, time, and location on Structure Beginning of each shift or location Ambient temperature Beginning of Work and then every 4 hours Dew point and humidity Beginning of Work and then every 4 hours Concrete Surface temperature to be coated with SSF II Beginning of Work and then every 4 hours Wet Film Thickness (WFT) per ASTM D4414* immediately following the application of the coating (WFT using a wet film thickness gauge provided by the manufacturer of the SSF II product) Determine and report the mean and range of the readings every 1/2 hour of application time or more as defined by the Engineer (if out of compliance take a reading every 10 minutes until in compliance) Visual inspection 100 percent Surface Preparation Prior to Coating 2401.3F.2, “Formed Surfaces,” and/or 2401.3F.2.b, “Sack Rubbed Surface Finish.” Pre-clean (grind, sand blast, water blast, vapor blast) Each component to receive an ordinary surface finish coating. Visually inspect 100 percent of concrete area that will receive SSF II and ensure that all applied release agents, curing compounds, dirt, grease, and other deleterious contaminants are completely removed 2401.3F.3, “Un-Formed Surfaces” Pre-clean (water wash if necessary) Visually inspect 100 percent for cleanliness Finish Coat: (Premixed Single Coat System) Batch/Lot number Every container Verification of surface cleanliness Examine visually within 1 hour before application Temperature of mixed product Just before application Complete mixing of all components in the shipping container Examine visually every container (no residual components left in container) Coating evaluation and repair Visual, 100 percent Recoat time As recommended by the manufacturer Coating system final evaluation and repair Visual, 100 percent * ASTM D4414, Measurement of Wet Film Thickness by Notch Gauges F.2.c(2) Application Requirements Do not start any SSF II coating application until the Engineer has written confirmation from the Department’s Laboratory Director that the product complies with initial color requirements. Cure concrete as required by 2401.3G, “Concrete Curing and Protection,” and the SSF II manufacturer prior to applying the surface coating. Prepare concrete that is older than 24 hours by power washing with potable water using a minimum of 3500 psi. Remove all efflorescence, flaking coatings, oil, curing compounds, release agents and other deleterious contaminants from the concrete surface prior to the application of the coating. Curing compound

and release agent must be completely removed and may require additional means beyond 3500 psi pressure washing, grinding, or blasting as approved by the Engineer. SSF II may be applied to “un-cured” or “damp” concrete surface per the manufacturer’s recommendations provided surface does not show liquid water droplets or pooling.

operations only when it is possible to perform the Work continuously from beginning to completion on any one Structure element

application cannot be accomplished then select coverage zones that will not produce an obvious start/stop delineation line

operations cannot start when the temperature of the substrate, coating, or ambient air temperature is outside the manufacturer’s recommended range. If no recommendation is given, use a minimum of at least 40°F and rising ambient air temperature. Suspend surface finishing operations if the ambient air temperature falls to 45°F and is dropping. Avoid application in direct sunlight to minimize a premature dry-out condition Single-component coatings require the SSF II product to be thoroughly mixed in its original container, then remixed as necessary and as recommended by the manufacturer to keep components in suspension and to incorporate the color pigments. If the SSF II product is shipped in 5 gallon containers, thoroughly mix the contents then completely empty all the contents into a larger container maintaining a minimum of 15 gallons of uniformly mixed product at all times. Equip the large container with an agitator during spraying. Provide an agitator or stirring rod capable of reaching within 2 inches of the bottom of the 15 gallon container to keep the product thoroughly mixed during application. Supply a manufactured SSF II product that doesn’t require thinning. Thinning of SSF II product is not allowed and the Engineer will reject all thinned SSF II product. Any SSF II product thinned and then applied will be required to be completely removed and replaced, at no cost to the Department. The Engineer will require the complete removal of all SSF II that is adversely affected by moisture within the first 24 hours after SSF II placement. Once all SSF II is removed, recoat concrete with SSF II to original specified requirements referenced above, at no cost to the Department. Apply one coat of the SSF II mixture by spray application only, using spray Equipment as recommended by the manufacturer. Use the minimum coverage rate of wet mils as defined on the APL for applying the Material. The Engineer will reject, require removal, and recoating of concrete with SSF II if runs, sags, excessive build-up, or overlap of texture causes a non- uniform appearance.

Perform surface finishing that produces a uniform color and texture on the cured surface. To prevent a non-uniform appearance “Tiger- Stripping” of the texture limit the overlap of each spray applied pass of the coating. The final SSF II surface finish will not have laps or breaks in continuity. Perform corrective Work on unaccepted finished areas coated with SSF II as directed by the Engineer, at no additional cost to the Department. Protect non-coated surfaces from overspray. If the Engineer determines that the overspray damage is non-conforming the Engineer will direct that the overspray be removed, at no additional cost to the Department. F.2.d Curb, Sidewalk, and Median Finish Provide a surface finish on formed surfaces of medians, delineator curbs, and the Roadway face of curbs and Sidewalks in accordance with the following:

the forms and Work continuously to completion. As the ordinary surface finish progresses, rub the surface with a cork float or fine Carborundrum stone to produce a paste on the surface and to expose and fill depressions and surface cavities. Float the paste to a smooth surface free of coarse texture, swirls, and ridges. Before the surface sets, brush the surface lightly with a fine bristled brush to remove cement films and produce a uniform surface with a fine grained and sanded texture

after concrete placement F.2.e Barrier Surface Tolerance Do not allow horizontal or vertical irregularities greater than 1/4 inch in any 10 foot length of finished concrete barrier. The Engineer may reject surfaces and edges not meeting this tolerance as unacceptable Work in accordance with 1512, “Unacceptable and Unauthorized Work.” Remove and replace unacceptable Work as directed by the Engineer. Remove and replace extensive areas (greater than 10 percent of barrier length) with deviations greater than 1/2 inch. If the Engineer does not direct the Contractor to remove and replace unacceptable Work, the Contractor may leave the Work in place with the following price adjustments:

concrete barrier at 75 percent of the Contract Unit Price

with deviations greater than 1/2 inch, the Department will pay for concrete barrier at 50 percent of the Contract Unit Price F.3 Unformed Surfaces F.3.a Miscellaneous Unformed Surfaces Finish unformed upper horizontal and inclined surfaces, except for the surface of Bridge Slabs and the surface at horizontal construction joints, in accordance with the following: Do not use steel trowels and steel shod floats. Use wood or wood shod templates and strike-offs. Use hand floats and darbies with wood, canvas, rubber, or cork contact surfaces. Use metal edgers that do not form offsets greater than 1/16 inch in the concrete surface. Do not create waves in the concrete surface when edging. In

lieu of using an edger, the Contractor may form rounded corners using a cove strip that does not create an offset greater than 1/16 inch with adjacent concrete surfaces. Place excess concrete in the forms and compact by internal vibration. After a 30 minute delay, strike off and screed the surface with a template forcing the coarse Aggregate below the finished surface leaving the surface slightly above finished elevation to allow for settlement during curing. Repeat the screeding and strike-off operation to obtain the elevation shown on the Plans and contour, except for edging. Waste laitance and excess mortar outside of the forms. After the final strike off and screeding, hand float the surface to correct irregularities and seal surface tears . Immediately after the water sheen leaves the surface, rework the surface to a uniform texture using a float. Tool rounded corners and edges to final radius forcing the coarse Aggregate beneath the finished radius. Float to remove trails left by the edging tools. Apply final texture and finish to the surface in accordance with the following:

Ramps, landings, and stair treads for pedestrian Bridges and tunnels in a transverse direction using a fairly stiff bristled brush or broom to produce a surface finish meeting the following requirements and characteristics:

grained, sanded texture using a fine bristled brush. Ensure the finished surface does not vary by greater than 1/8 inch from a 10 foot straightedge laid longitudinally on the surface, with transverse surfaces substantially as shown on the Plans. F.3.b Bearing Seats F.3.b(1) Prior to casting bearing seats Construct the bearing seat forms, at time of form setting, within a 0.01 foot accuracy tolerance. The contractor may elect to build bearing seat forms at a higher elevation with subsequent grinding to come back into elevation tolerance provided no ponding areas result on top of the bearing seat. If bearing seats are built to a higher elevation, increase top concrete cover by the same amount. Where anchor rod blockouts are incorporated within the forms, the blockouts may be tied individually or with a template rigidly joining a blockout group. All anchor rod blockouts at a given bearing seat comprise a blockout group. The location tolerance for individual blockouts is 1/16 inch within the blockout group. Position the blockout group to enable placement of the bearing assembly within 1/4 inch of the Plan center bearing position. Refer to the Plan and adhere to all requirements of 2472.3C, “Placing, Supporting, and Tying Bar Reinforcement.” Survey the center of individual blockouts prior to casting concrete and provide the X and Y coordinate data to the Engineer. Adjust any blockouts that are out of tolerance. Survey final blockout positions and provide the X and Y coordinate data to the Engineer.

F.3.b(2) After meeting the curing requirements as specified for bearing seat concrete Grind the Bridge seats to produce a level surface area that does not vary by greater than 1/16 inch for steel base plates or by greater than 1/8 inch for elastomeric bearing pads. The level surface area is defined as an area with a boundary 2 inches outside the bearing contact area on all sides. Grind surfaces outside the level surface area to prevent ponding. Adjust the level surface area if any of the tolerances are exceeded. After grinding the level surface area, field-survey bearing seats at center of bearing and provide an electronic copy of the X and Y coordinates and elevations to the Engineer. When anchor rod blockouts are cast into the bearing seat, survey the center of each blockout position and provide the information to the Engineer. F.3.b(3) Adjustments to Leveled Bearing Seats Prior to adjusting any level surface areas or bearing seats, submit the proposed method, Material specifications, and required adjustment for each bearing seat to the Engineer. The Engineer must accept the correction proposal in writing prior to proceeding with any Bridge seat modifications. Adjust the level surface area when the differential between adjacent level surface areas deviates by more than:

specified in 2471,”Structural Metals”

The differential between adjacent bearings (Δ) can be calculated as follows: Δ = |(Plan elevation beam A – survey elevation beam A) – (Plan elevation beam B – survey elevation beam B)| At a given line of bearing or within the same Substructure, produce bearing seats within the following accuracy:

elevation for the lowest seat at a given Substructure

elevation for the highest seat at a given Substructure The Plan elevation in the sections above mean the bearing seat elevation shown in the Bridge Plans adjusted for the actual bearing heights which have been approved by the Engineer. F.3.c Bridge Slabs F.3.c(1) General Before placing concrete for a section of Bridge Slab, and after setting the strike-off rails or guides to correct elevation, check the top reinforcement for vertical position by operating the strike-off on the rails or guides in the presence of the Engineer. Attach a filler strip 1/4 inch thinner than the minimum concrete cover requirements to the bottom of the strike- off

during this check to detect reinforcement bars that may encroach on the required clearance. Place any of the following in a continuous operation proceeding uniformly from edge to edge of the slab or from end to end of the section:

a joint

If the Contract does not require a specific sequence or direction for casting slab sections, submit Plans for the proposed casting procedures for approval. Before starting construction, obtain the Engineer’s approval for any change to the casting Plans. If Bridge Slab placement and finishing is performed at night, provide a Well-Lighted area to accomplish QC/QA inspections. If at least two spans of continuous beams or girders support a Bridge Slab section, place concrete at a rate that concrete will remain plastic for at least one-half a span length back of an intermediate support until placement has proceeded to a point one-half of the span length ahead of that support. Provide approved admixtures to retard concrete setting time as required to maintain plasticity. If simple span girders support a Bridge Slab section or if the Contract requires sequence casting for wide continuous beam Bridge decks, place concrete at a forward rate of at least 20 feet per hour without producing cold joints between partially hardened concrete and the adjacent newly placed concrete. At least 14 Calendar Days prior to slab placement, provide a slab placement and curing Plan for each Bridge to the Engineer for approval. Include the following information in the placement and curing Plan:

finishing, and curing including placement of wet burlap, soaker hose, or other system to maintain the deck in a moist condition during the curing period

the Contractor cannot maintain the proposed concrete placement rates

Attend a pre-placement meeting 2-4 Calendar Days before the slab placement to review the information and details provided in the placement and curing Plan. The following project personnel are required to attend the pre-placement meeting:

F.3.c(2) On-site Adjustments for Bridge Slab Concrete In addition to the requirements set forth in 2461.3G.4, “Field Adjustments,” comply with the following if any adjustments are necessary on site:

be allowed with the exception that viscosity modifying admixture (VMA) may be used to adjust slump

of concrete, including the any water necessary to dilute admixtures, may be on site provided that additional water is available to add per the Certificate of Compliance

after any additions The Engineer will not allow finishing aids or evaporation retarders for use in finishing of the concrete. F.3.c(3) Trial Bridge Deck Placement for HPC A minimum of 14 Calendar Days prior to the actual placement of the Bridge Deck Slab concrete, successfully complete a separate trial placement utilizing a minimum of two 10 cubic yard loads. The Engineer may allow the incorporation of the concrete for trial batches into the Bridge footings, abutments, or end diaphragms. The Contractor may also choose to incorporate the trial batches into residential/commercial construction in the immediate vicinity of the Project. In any case, the Engineer will require mixing, transporting, and placing the concrete using the same methods as the actual placement of the Bridge deck. If the concrete is incorporated into the permanent Work, the Engineer will test the plastic concrete in accordance with the Schedule of Materials Control. The Engineer may require additional trial batches if the concrete delivered to the Project does not comply with the plastic concrete requirements of the Contract. The Engineer will waive a trial placement, at the Contractor’s request, provided the Contractor submits a history of at least 3 successful Bridge deck placements in the last 5 years using the same mix design and similar pumping or placement configuration. The concrete mix design, laboratory batching and mixing, and the trial placement are included in Bridge Slab Concrete.

Use the same Materials, same supplier, same supplier’s manufacturing plant, and proportions in the permanent Work as in the trial placement. Strength requirements specified for each mix are applicable to the cylinder tests taken during the production Work. F.3.c(4) Strike-Off of Bridge Slab (Applies to both Bridge Deck Slab and Bridge Structural Slab) Place the concrete at a rate that ensures the initial strike-off operation is never greater than 10 feet behind the placement operation. Maintain the head of concrete parallel with the initially screeded surface. Leave excess concrete carried in front of the screed on the surface when reaching the head of the concrete. Mix with freshly deposited concrete before compacting. Consolidate any previously consolidated concrete to remove voids, including those caused by footprints or reinforcement deflection. Strike off and screed the Roadway surface after concrete placement and compaction. When the initial strike-off operation reveals low areas, fill these areas with additional concrete before continuing . Avoid walking in the concrete after the initial pass of the screed. Re-screed to the cross-slope and longitudinal profile as required by the Contract. Do not Work, smooth, or disturb the concrete surface while bleed water and laitance remain on the surface. If the use of a power-operated strike-off screed is specified, provide mechanical screeding motion with Equipment moving on flanged or grooved wheels resting on the screed rails. If exterior beams or girders that lie under the Roadway slab support the running rails, the Contractor may finish the area between the rail and the gutter without the use of the power- operated screed. In this area, use suitable guides to determine the required gutter profile and, after plastic shrinkage, straighten and true the are a to the required profile and cross-slope. Ensure the screed carries a surplus of concrete in the front during screeding operations. Perform the final screeding to cover as long a section as practicable without stopping. Remove at least the upper 4 inches of screed rail supports and fill void with concrete. Any supports left in the deck shall be epoxy coated or galvanized. Bridge Structural Slabs The Department will not require screed rails for templates used for strike-off and screeding of a Bridge Structural Slab. If using screed rails, use screed rails in accordance with this section. Securely tie and rigidly support top reinforcement in accordance with 2472.3C, “Placing, Supporting, and Tying Bar Reinforcement.” Before placing the concrete, demonstrate that the Equipment and methods proposed for use will not damage or displace reinforcement bars. Provide additional bar support, additional supports for template, or both upon visible deflections of reinforcement. Demonstrate adjustments for crown breaks as approved by the Engineer. Evenly attach vibrators across template length and provide templates that will automatically shut-off vibration when forward motion stops.

Space template supports to prevent sag in the template. For portions of template supports in contact with reinforcement, provide template supports consisting of round tubes or rods with a smooth, low friction surface . Provide skis at least 5 feet long with a gradual “turn-up” nose sufficient to prevent entrapment in reinforcement. Support transverse reinforcement bars within 6 inches of the location where template support skis will ride. Provide a manual or powered winch to advance the template. Do not anchor winch cables to reinforcement bars. The Contractor may attach the winch cable to beam shear studs or stirrups. Spread and level concrete in front of template without causing “float” or overriding. Hand-float the surface of Bridge Structural Slabs only to close up areas of exposed Aggregate. Bridge Deck Slabs (Bridge slabs without separate concrete wearing course) Use a self-propelled power-operated strike-off machine to screed the Roadway surface of monolithic Bridge Deck Slabs. Provide a finishing machine consisting of a cylindrical finisher mated with horizontal adjustable augers, both of which are mounted on a transversely moving carriage. Sidewalk surfaces to be separated by a permanent concrete barrier may be screeded with strike off Equipment conforming to 2401.3F.3.c(4), “Strike-off of Bridge Slab (Applies to both Bridge Deck Slab and Bridge Structural Slab),” meeting the finish tolerances for Bridge Deck Slabs. Use rails, bulk-heads, or the side forms as screed guides for manual strike-off. Use rails as guides for power-operated strike-offs, with provisions for vertical adjustment. Support the screed rails for power-operated screeds on the exterior beams, girders, or webs of the Structure. Provide calculations and obtain the Engineer’s approval if planning to support screed rails on the side forms or on any falsework independent of the Superstructure. Construct screed rails in a manner that will allow vertical adjustment after concrete is placed on concrete deck girders and concrete slab span Bridges. During concrete placement, check elevations and vertically adjust if necessary. For full depth monolithic decks, the finishing machine will consist of a cylindrical finisher mated with horizontal adjustable augers, both of which are mounted on a transversely moving carriage unless otherwise approved by the State Bridge Construction Engineer. A 10 foot Highway straightedge is required for full-depth decks prior to carpet dragging regardless of whether texture planing is specified for the final ride surface. Float slab in accordance with Bridge Construction Manual 5-393.358 to ensure the final surface does not vary by greater than 1/8 inch within a 10 foot straightedge laid longitudinally on the final surface. This surface tolerance includes areas near expansion devices and other breaks in the continuity of the Bridge Slab.

If an outside webwall of a box girder is under a Sidewalk or curb, the Contractor may modify the Sidewalk or curb reinforcement to accommodate the running rail system for the power strike-off machine as approved by the Engineer and at no additional cost to the Department. F.3.c(5) Final Finish Texture Draw a carpet drag longitudinally along the Bridge Slab before the concrete attains its initial set to obtain a final finish texture. Adjust the carpet drag to produce a texture accepted by the Engineer. Use a carpet drag meeting the following characteristics and requirements:

In lieu of the carpet drag texturing, the Contractor may use coarse broom texturing as accepted by the Engineer. Texture the Roadway surface as accepted by the Engineer to produce a final surface serrated, grooved, or roughened greater than that normally produced by conventional brooming. Do not tear out or loosen particles of coarse Aggregate during texturing. Produce a final surface, including areas near expansion joints, meeting the following requirements:

Structural Slab when checked with a 10 foot straightedge placed longitudinally

Slab when checked with a 10 foot straightedge placed longitudinally Immediately following the carpet drag, texture final Roadway surfaces with a metal-tine pattern unless a diamond-ground texture is scheduled for the surface as part of the Contract. Install the transverse texturing (tining) on a slight diagonal, at an angle of approximately 10 degrees to a line perpendicular to the Roadway centerline, produced by using a device meeting the following characteristics and requirements:

from 1/12 inch to 1/8 inch thick

1/8 inch to 5/16 inch deep

The Contractor may use other texturing Equipment that will produce an equivalent texture as accepted by the Engineer. Do not texture within 1 foot of curbs. F.3.c(6) Bridge Slab Finish Under Curbs, Concrete Barriers, Sidewalks, and Medians Float the top surface of the Bridge Slab under curbs, concrete barriers, Sidewalks, and narrow medians producing a rough surface with the coarse Aggregate embedded in mortar. Provide a smooth finished strip 2 inches wide at the edge of the slab and under the Roadway face of curbs, concrete barriers, Sidewalks, and narrow medians. Choose one of the following alternates to prepare the top surface of the Roadway slab directly under island type medians:

laitance. Apply a cement bonding grout to the concrete consisting of Portland cement mixed with water forming a slurry having the consistency of paint before placing median concrete. Place median concrete on wet bonding grout.

reinforcement bars (dowels) into the slab parallel to each median gutterline. Place the dowels 1 foot in from the gutterlines at 2 foot centers. Drill the dowels at least 4 inches into the Roadway slab and projecting 4 inches into the median concrete. Anchor the dowels with an approved epoxy or approved non-shrink grout. F.3.c(7) Bridge Slab Finish for Bottom Slab Concrete Box Girders Strike off the top surface of the concrete in the bottom slab of concrete box girders and finish to within a 1/4 inch tolerance when checked with a 10 foot straightedge. The Department will not require additional finishing of this surface. F.3.c(8) Surface Smoothness Check After completion of the curing period, the Engineer will check the Bridge Deck Slab surface for trueness, using a 10 foot straightedge for transverse and longitudinal checks. The Engineer will perform at least 2 longitudinal checks in each Traffic Lane and 1 check at each gutter. Sweep the surface clean of debris before the Engineer performs the checks. Correct surfaces outside of the specified tolerance of a 10 foot straightedge in accordance with 2401.3F.3.c(5), “Final Finish Texture.” Mill high spots. Remove concrete in low spots designated for removal to at least 2 inches below required grade and then recast to the proper grade with an approved product. Restore removed tine texture. The nonconforming areas not satisfactorily corrected are subject to 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” Remove high spots before filling adjacent depressions . If not placing a wearing course, coat areas corrected by surface grinding with a surface sealer listed on the APL, Concrete, “Bridge penetrating sealer.”

G Concrete Curing and Protection Cure newly placed concrete by providing protection against the following:

Vibration”

Should any damage result, the Engineer will suspend operations until corrective action is taken and may subject the damaged concrete to 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” Perform the following for defective sections as directed by the Engineer:

Whenever weather conditions are such as to cause unusual or adverse placing and finishing conditions or Equipment failures occur, expedite the application of a curing method or temporarily suspend the mixing and placing operations, as the conditions require. G.1 Minimum Curing Period For the purpose of the Work in section 2401.3, “Concrete Bridge Construction, Construction Requirements,” the Department defines the “curing period” as the time of maintaining satisfactory moisture and temperature in concrete during the period immediately following placement through the specified duration, so that hydration of the cement may continue until development of the desired properties to a sufficient degree to meet the required service life. In no case, will the concrete surface show evidence of drying which includes surface color changes during the curing period. Maintain a minimum concrete surface temperature of 40°F or greater during the curing period. If the concrete surface temperature drops below 40°F during the curing period, notify the Engineer and make adjustments to the curing to raise the surface temperature above 40 °F as prescribed in the curing Plan. If the concrete surface temperature drops below 40°F during the curing period, add one additional day to the minimum curing period for each day the temperature drops below 40°F. Provide additional protection as required in accordance with 2401.3G.5, “Protection Against Cold Weather.” The Engineer may allow some modification of the requirement for continuous curing without interruption for the purpose of setting wall or column forms on footings, but only when the Contractor protects the concrete from freezing or excessive drying during the interruption period. Resume curing at the earliest opportunity, and cure until completion of the curing period. If using heated enclosures during the curing period, vent heaters and other E quipment operated within the enclosure to prevent the buildup of carbon dioxide. When the Plans show a permissible construction joint, the Contractor may begin subsequent concrete placement before completion of the curing period, unless otherwise shown on the Plans.

Determine the minimum curing period for a given element in accordance with Table 2401.3-2 and the following:

removal

barriers when the concrete can retain its shape and if weather conditions allow the start of the specified concrete finish per 2401.3F.2.d, “Curb, Sidewalk, and Median Finish,” immediately after removing the forms. Other forms are required to remain in place for at least 24 hours after casting the concrete or longer if stripping the forms will damage the concrete or prevent disengaging the form ties, unless otherwise noted in Table 2401.3-2

100 percent curing coverage within 30 minutes for each formed face. The Engineer may consider revisions to the 30 minute requirement for continuous curing based on field conditions, measured evaporation rates, and the submitted curing Plan in accordance with 2401.3G.3, “Curing Plan”

surface remains moist for duration of curing period

Table 2401.3-2 Curing Requirements for Concrete Bridge Elements For all formed and unformed concrete (Do not use for Mass Concrete) Bridge Element Minimum Curing Period Minimum Period For Form Cure Minimum Strength Required to Pull Forms, psi Minimum Strength to Apply Loads, percent of Required † Method Allowed to Determine In-place Concrete Strength Bridge Superstructures, unless otherwise specified 96 hours 24 hours 2000 ǂ 65 Maturity or Control Cylinders Slab Span Superstructure 7 Calendar Days 8 Calendar Days See Special Provisions See special provisions Maturity or Control Cylinders Diaphragms and end webs not a part of box girders and cast before the Bridge Slab 72 hours 24 hours 2000 ǂ 45 Maturity or Control Cylinders Pier Caps 72 hours 72 hours 2000 ǂ 65 Maturity or Control Cylinders Retaining Walls 72 hours 12 hours * Self- supporting 100 Maturity or Control Cylinders Barriers and Parapets 72 hours - Self- supporting 45 ǁ Maturity or Control Cylinders Sections not included in Superstructures, unless otherwise specified 72 hours 24 hours 2000 ǂ 45 Maturity or Control Cylinders Bridge Slab # 7 Calendar Days - - 100 § Maturity or Control Cylinders Bridge Slab Underside # 7 Calendar Days 8 Calendar Days 2000 100 - * When weather conditions require cold weather protection in accordance with 2401.3G.5, “Protection Against Cold Weather,” increase form curing to a minimum of 24 hours. ǁ Achieve 4000 psi prior to use as a traffic barrier. † Applied loads include but are not limited to Equipment, beams, backfilling, or successive concrete placements. ǂ The Engineer will require verification of the minimum strength when air temperatures drop below 40°F during the curing period or when the mix design includes greater than 15 percent cement substitution. The minimum strength requirement does not apply to bulkheads and edge of deck forms . # See Table 2401.3-4 for Bridge Slab curing method. § See 2401.3G.6.e, “Protection from premature loading” for special loading allowances after wet cure and prior to specified strength.

G.2 Acceptable Curing Methods Cure concrete in accordance with Table 2401.3-3. Use methods necessary to comply with the minimum curing period. Do not apply membrane curing compound to construction joints, or to concrete surfaces which are planned for bonding to other concrete, waterproofing, applying sealants or special surface finish, except as allowed in accordance with Table 2401.3-3. Ensure steel reinforcement, anchors, waterstops, and similar devices are free of membrane curing compound prior to placing concrete. Table 2401.3-3 Acceptable Curing Methods (Do not use for Mass Concrete) Element Special Surface Finish Required Membrane Curing Method (2401.3G.2.a, “Membrane Curing Method”) 2401.3G.2.b, “Curing Blanket Method” Wet Curing Method (2401.3G. 2.c, “Wet Curing Method”) 2401.3G.2.d, “Formed Curing Method” Single Component SSF II Cure Method (2401.3F.2.c, “Special Surface Finish”) 3754, “Poly- Alpha Methyl styrene (AMS) Membrane Curing Compound” 3753, “Type 1-D Membrane Curing Compound” Footing No Yes Yes Yes Yes Yes N/A Pier Cap Yes No No Yes Yes Yes Yes Pier Column Yes No Yes* Yes Yes Yes Yes Abutment, Retaining Wall and Wingwall Front Face Yes No Yes* Yes Yes Yes Yes Back Face No Yes Yes Yes Yes Yes N/A Concrete Barrier, Parapet, and End Post All Faces of Surface Yes No Yes* Yes Yes Yes Yes Pier Strut Yes No No Yes Yes Yes No Cast-in-Place Box Culvert No Yes No Yes Yes Yes N/A Sidewalk, Raised Median No Yes No Yes Yes N/A N/A Coping, Edge of Slab Yes No No Yes Yes Yes No Bridge Deck Slab or Bridge Deck No Refer to 2401.3G.6, “Concrete Bridge Deck Curing and Protection” * The Engineer will allow the use of curing compounds meeting 3753, “Type 1-D Membrane Curing Compound,” provided a letter from the special surface finish manufacturer states the proposed curing compound is compatible with the special surface finish. Remove remaining membrane curing compound that has not completely dissipated from the surface prior to applying special surface finish. Removal will be required by means of sandblasting, grinding , or other approved methods.

G.2.a Membrane Curing Method Use membrane curing compound meeting the requirements of 3754, “Poly- Alpha Methyl Styrene (AMS) Membrane Curing Compound,” or 3753, “Type 1-D Membrane Curing Compound.” Use the same type of curing compound on the entire individual element. Before application, agitate the curing compound as received in the shipping container to obtain a homogenous mixture. Protect membrane curing compounds from freezing before application. Handle and apply the membrane curing compound in accordance with the manufacturer’s recommendations. Apply the curing compound in accordance with the following:

area

white, opaque coverage on all exposed concrete surfaces (equal to a white sheet of copy paper). If using a Department approved curing compound with a non-white base color, apply the compound to provide a uniform, solid, opaque consistency meeting the intent of the requirement in this section

immediately repair the damaged area by respraying

in unsatisfactory curing, the Engineer may require the Contractor to use an alternate curing method, at no additional cost to the Department Use an airless spraying machine that complies with the following:

the reservoir Material

patterns G.2.b Curing Blanket Method After completion of the finishing operations and without marring the concrete, cover the concrete with pre-wetted burlap or curing blankets. Install in a manner that envelops the exposed concrete and prevents loss of water vapor. Six mil (minimum) white plastic sheeting over a layer of wet burlap or a wet curing blanket is a method of cure in which the loss of mixing water is minimized due to the tight nature of the cover. Install the envelope in accordance with the following:

12 inches at the seams to maintain a reasonably air tight seal. Secure the edges of the sheeting by any means satisfactory to the Engineer to provide an air-tight cover

by wire or rope fasteners. They should be held in position on Roadway and Sidewalk slabs by holding down the burlap or blankets with sand or lumber at the joints and edges

add water as necessary to assure that the concrete surface is moist at all times

reinforcement is exposed use one of the following methods:

drape plastic over the tops of the reinforcement, and weigh down the plastic adjacent to the exposed areas

burlap or curing blankets with the reinforcement projecting through the plastic sheeting. Do not allow the burlap or curing blankets to dry out during the curing period G.2.c Wet Curing Method Cover the surface of the concrete with pre-wetted burlap as soon as the concrete has hardened sufficiently to prevent marring the surface. Pre -soak the burlap for a minimum of 12 hours prior to placement. Overlap the burlap a minimum of 12 inches. The Engineer will not allow the application of dry burlap and then sprayed down with water as an acceptable wet cure method. Overlap spray with soaker hoses or sprinklers to keep unformed surfaces continuously wet for the minimum curing period, unless another curing method is used. Use water for curing in accordance with 3906, “Water for Concrete and Mortar.” Limit the amount of water applied to the amount that will keep the concrete wet without running sheets or streams. If the concrete surface shows evidence of erosion by the curing water, the Engineer will immediately suspend the spraying or fogging. Remedy the conditions causing erosion or switch to another cure method that does not involve continuous wet cure. If the National Weather Service forecast for the construction area predicts air temperatures to fall below 32°F within the next 24 hours, suspend conventional wet curing and switch to another acceptable curing method in accordance with 2401.3G.5“Protection Against Cold Weather.” G.2.d Formed Curing Method When forms are left in direct contact with the concrete, other curing methods are not required except for exposed surfaces and for cold weather protection. Use another acceptable curing method if forms are removed prior to completion of the minimum curing period. G.3 Curing Plan At least 14 Calendar Days prior to any concrete placement, provide a curing Plan to the Engineer for acceptance, in writing. Submit a separate curing Plan for the Bridge Deck in accordance with section 2401.3F.3.c(1), “General,” and 2401.3G.6, “Concrete Bridge Deck Curing and Protection.” A sample curing plan is available upon request. Include the following information in the curing Plan:

curing Plan

compounds

surface finish over any membrane curing compounds products

greater during the curing period. Action plan to restore surface temperature should the temperature drop below 40°F

weather protection Plan in accordance with 2401.3G.5, “Protection Against Cold Weather”

minutes, include a table stating what expected weather conditions at time of form removal and applicable curing requirements are necessary to ensure a maximum evaporation rate of 0.3 pounds per square feet per hour is not exceeded. Reference Figure 2401.3-1 and ACI 305.1-14, Specification for Hot Weather Concreting, Section 3 for additional information on methods for calculating evaporation rates. Figure 2401.3-1 Nomograph for Estimating Evaporation Rate

For each structural element, complete the Concrete Curing Quality Control Form on the Bridge website. Submit completed forms to the Engineer within 7 Calendar Days of completing the structural element. Failure to adhere to the Engineer accepted Contractor’s curing Plan or observation of any surface drying during the curing period will result in a curing qualification period as follows:

to remain in place for the minimum curing period

presence of the Engineer prior to reinstating the curing Plan on new Work G.4 Protection Against Rain Protect the concrete from damage due to rain or snow. Have available, near the site of the Work, Materials for protection of the edges and surface of the concrete. Should any damage result, the Engineer will suspend operations until corrective action is taken and may subject the rain or snow damaged concrete to 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” Do not start concrete placement when it is raining or snowing. G.5 Protection Against Cold Weather Protect the concrete in accordance with the Engineer accepted cold weather protection Plan during the following periods:

The Engineer will not permit the membrane curing method during the dates specified herein. The Engineer will base anticipated concrete placement and curing temperatures on weather forecasts or on typical temperature data for the time of year at the location of the Structure. Preheat the forms, in-place concrete, reinforcement bars, and items including the top flanges of beams to a minimum of 40°F when the temperatures of these surface areas are below freezing before placing concrete. Do not apply flames directly to concrete or steel. Provide insulated forms, insulation, or heating and housing facilities to maintain a concrete surface and projecting reinforcing temperature of between 60°F and 120°F during the curing period. The Engineer may allow the concrete surface temperature of betw een 50°F and 120°F for concrete with strengths equal to or greater than 75 percent of the required compressive strength but not less than 4,000 psi. Protect all exposed concrete surfaces within the heated enclosures from drying and carbonation throughout the curing period by using one of the acceptable curing methods and:

Keep the forms, insulation, and housing enclosure in place until the completion of cold weather protection as defined in 2401.3G, “Concrete Curing and Protection.”

Gradually discontinue the use of cold weather protection so the rate of temperature reduction adjacent to the concrete surfaces does not exceed 20°F during any 12 hour period until the surface temperature reaches the ambient air temperature. G.5.a Cold Weather Protection Plan Submit a proposed time schedule and written Plans for cold weather protection of concrete to the Engineer for acceptance that provides provisions for adequately protecting the concrete during placement and curing. Do not place concrete until the Engineer provides written acceptance of the cold weather protection P lan. G.6 Concrete Bridge Deck Curing and Protection G.6.a Prior to Beginning Bridge Deck Concrete Placement Three hours before the anticipated time of beginning the Bridge deck concrete placement, the Contractor will provide a National Weather Service forecast to the Engineer. The Engineer will review the forecast with the Contractor to confirm:

to 2 hours after the placement duration

window

temperature, and wind velocity produces an evaporation rate of less than 0.20 pounds per square foot of surface area per hour. Reference Figure 2401.3-1 and ACI 305.1-14, Specification for Hot Weather Concreting, Section 3 for additional information on methods for calculating evaporation rates. G.6.b Curing Method The Contractor is fully responsible for curing methods. Cure the concrete Bridge deck in accordance with Table 2401.3-4, unless other methods are approved by the Engineer in writing.

Table 2401.3-4 Required Curing Method Based on Final Bridge Deck Surface Bridge Deck Type Final Bridge Deck Surface Required Curing Method ǁ Bridge Structural Slab curing (3YHPC-S) (3YLCHPC-S) (3Y42-S) Low Slump Wearing Course Conventional wet curing after carpet drag Bridge Deck Slab curing (3YHPC-M) (3YLCHPC-M) (3Y42-M) Epoxy Chip Seal Wearing Course or Premixed Polymer Wearing Course Conventional wet curing after carpet drag Bridge Deck Planing Conventional wet curing after carpet drag Tined Texturing* Conventional wet curing after tine texturing. AMS curing compound after wet cure period Finished Sidewalk or Trail Portion of Deck (without separate pour above)* Conventional wet curing after applying transverse broom finish AMS curing compound after wet cure period * Prevent marring of broomed finish or tined textured surface by careful placement of wet curing. ǁ Apply conventional wet curing to Bridge Slab following the concrete finishing.

Use conventional wet curing consisting of pre-wetted burlap covered per 3751, “Burlap Curing Blankets,” with 6 mil (minimum) white plastic sheeting per 3756, “Plastic Curing Blankets,” and in accordance with the following:

openings

defined in 2401.3F.3.c(4), “Strike-Off of Bridge Slab (Applies to both Bridge Deck Slab and Bridge Structural Slab),” of the concrete surface (failure to place the wet curing within 30 minutes will constitute a Department monetary deduction as specified in 2401.5A.2, “Concrete Curing and Protection”)

least 7 Calendar Days

After 96 hours, the Engineer may allow some modification of the requirement for continuous curing without interruption for the purpose of tying barrier reinforcement bars. Restrict the interrupted area to within 2 feet of the barrier. Protect the concrete from freezing or excessive drying during the interruption period. Resume curing at the earliest opportunity, and cure until completion of the curing period. Where marring of the broomed finish or tined texturing surface finish of Bridge Deck Slabs is a concern, the Engineer may authorize curing as follows:

3754, “Poly-Alpha Methyl Styrene (AMS) Membrane Curing Compound,” using an approved power-operated sprayer in accordance with 2401.3G.2.a, “Membrane Curing Method”

Material on exposed concrete surfaces (equal to a white sheet of copy paper). This may require use of a Work Bridge to access the center portion of the deck

defined in 2401.3F.3.c(4), “Strike-Off of Bridge Slab (Applies to both Bridge Deck Slab and Bridge Structural Slab),” of the concrete placement (failure to place the curing compound within 30 minutes will constitute a Department monetary deduction as specified in 2401.5A.2, “Concrete Curing and Protection,” unless otherwise directed by the Engineer)

of conventional wet curing

not produce imprints deeper than 1/16 inch

of at least 7 Calendar Days

on any concrete surface that will receive future placement of additional concrete or wearing course on that surface G.6.c Superstructure Protection Against Cold Weather Protect the concrete against cold weather in accordance with 2401.3G.5, “Protection Against Cold Weather,” and the following: Provide imbedded temperature sensors and monitoring devices for Bridge Slabs. Provide a minimum of two sensors and at least one additional sensor per 5,000 square feet of Bridge Slab. Place sensors at locations agreed to by the Engineer. G.6.c(1) Bridge Slabs, Box Girder Bottom Slabs, and Box Girder Webs Place and cure concrete in Bridge Slabs, box girder bottom slabs, and box girder webs in accordance with the following:

place concrete only after placing housing needed to heat the pour area and maintain required pour temperatures of at least 60°F.

placement but is anticipated to fall below 34°F during curing, do not place concrete until as much insulation or housing and heating are in as needed to protect the concrete from freezing. The Contractor may install insulation and housing after completion of concrete finishing, as approved in the cold weather protection Plan if the insulation and housing hinders concrete placement.

G.6.d Bridge Deck Slab Dry Out Period A dry-out period is required for Bridge Deck Slabs cast after October 14 and opened to traffic prior to April 15 of the following year. For 21 Calendar Days after removing the curing Material or until April 15, whichever comes first, heat and provide housing to ensure free air circulation above the concrete surface to dry the concrete and prevent the temperature of the concrete from falling below 40°F. G.6.e Protection from premature loading Do not allow vehicles or Equipment on the Bridge Slab until after completion of the curing period and minimum strength requirements of Table 2401.3-2. Reinforcement bar bundles or pallets may be placed on the Bridge Slab after 96 hours provided the loading is not greater than 1,000 pounds per 100 square feet area. G.6.f Bridge Deck Cold Weather Protection Plan Submit a proposed time schedule and Plans for cold weather protection of the Bridge deck in writing to the Engineer for acceptance that provides provisions for adequately protecting the concrete during placement and curing. Do not place concrete until the Engineer accepts the cold weather protection Plans. G.7 Protection of New Concrete against Vibration Do not subject freshly placed concrete to excessive vibration and shock waves during the curing period until it has reached a 2,000 psi minimum compressive strength for structural concrete and lower-strength classes of concrete. After the first 5 hours from the time the concrete has been placed and consolidated, keep all vibration producing operations at a safe horizontal distance from the freshly placed concrete by following either the primary or alternate method. Plant cast concrete is not subject to these requirements. G.7.a Primary Method – Prescriptive Safe Distance Method After the concrete has been placed and consolidated, keep all vibration producing operations at a safe distance from the freshly placed concrete as shown in Table 2401.3-5. After the concrete has reached the minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply. Table 2401.3-5 Safe Horizontal Distance Minimum Compressive Strength, f’c Equipment Class L * (Low Vibration) Equipment Class M ǁ (Medium Vibration) Equipment Class H † (High Vibration) < 1,000 psi 10 feet 75 feet 125 feet 1,000 to < 1,400 psi 10 feet 30 feet 50 feet 1,400 to 2,000 psi 10 feet 15 feet 25 feet * Equipment Class L includes small rubber tire construction Equipment like backhoes under 50,000 pounds, concrete placing Equipment, and legal Highway vehicles if such Equipment travels at speeds of ≤ 5 mph on relatively smooth Roadway surface or ≤ 3 mph on rough Roadway surface (i.e., with potholes). ǁ Equipment Class M includes tracked dozers under 85,000 pounds, track vehicles, trucks (unless excl uded above), hand-operated jackhammers, cranes, auger drill rig, caisson drilling, vibratory compacting rollers under 30,000 pounds, and grab hammers. † Equipment Class H includes pile drivers, vibratory hammers, machine -operated impact tools, pavement breakers, and other large pieces of Equipment.

G.7.b Alternate Method – Monitoring Safe Distance Method Monitor the vibration producing operations in order to decrease the safe horizontal distance requirements of the Prescriptive Safe Distance m ethod. Monitor all construction operations that produce vibration or shock waves in the vicinity of freshly placed concrete with monitoring Equipment sensitive enough to detect a minimum peak partial velocity (PPV) of 0.01 inches per second. Place monitoring devices on or adjacent to the freshly placed concrete when the measurements are taken. During the time subsequent to the concrete placement, cease all vibration or shock producing operations in the vicinity of the newly placed concrete when monitoring E quipment detects excessive vibration and shock waves defined as exceeding the PPV’s in Table 2401.3-6. After the concrete has reached a minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply. Table 2401.3-6 Peak Partial Velocities Minimum Compressive Strength, f’c Maximum PPV < 1,000 psi 0.01 inch per second 1,000 to < 1,400 psi 1.0 inch per second 1,400 to 2,000 psi 2.0 inch per second H Slipforming of Bridge Barrier Instead of using conventional forming methods, the Contractor may slipform concrete Bridge barrier in accordance with the following requirements: H.1 Reinforcement Bars Create rigidity of the bar cage by tying 100 percent of the reinforcement bar intersections in the barrier. Do not tack weld reinforcement bars . Place reinforcement in accordance with 2472, “Metal Reinforcement.” H.2 Concrete Mix Use 3S12 concrete mix design for slipformed barrier. The Engineer will reject concrete with a slump greater than 1 1/4 inch. H.3 Construction Requirements Perform the following construction requirements:

in the presence of the Engineer. During this check, attach fill strips to the slipformer to detect areas of reinforcement bars that may encroach on the required concrete cover. Perform this check for the full distance of the anticipated subsequent pour area, less any areas of hand-formed barrier

points immediately before slipforming barrier. Keep the contact surfaces wet until the fresh concrete is placed on them. Insert rigid plastic extrusion at control joints as per Plan details before placing the curing Materials

within 24 hours of the concrete placement to a width of 3/8 inch

the APL

each side of areas that the slipform machine cannot access

Contractor may increase the slab overhang by no greater than 1 inch and batter the outside of the barrier by no greater than 1 inch

the slipformer

immediately following the machine. Use conventional wet curing consisting of pre-wetted burlap covered with separate white plastic sheeting or cover with pre-wetted poly-coated burlap. Place the burlap to cover 100 percent of the barrier area without visible openings. Place the wet curing within 30 minutes after the machine completes the final strike-off of the concrete surface. Keep the barrier surface continuously wet for an initial curing period of at least 7 Calendar Days I Joint and Crack Sealing I.1 Joint Sealing Place joint sealer Material of the type as shown on the Plans or Special Provisions in accordance with 2301.3N.3, “Joint Sealing.” Complete concrete curing prior to installation of sealing Materials. A minimum of 14 Calendar Days drying is required prior to application of sealers. Sawcut joints, sandblast, blow clean, and ensure the concrete surfaces are dry at the time the sealer is installed . Perform Work as per manufacturer's recommendations. Construct preformed joint(s) as detailed in the Plans and in conformance with the following requirements.

Preformed Expansion Joint Filler for Concrete (Bituminous Type),modified to the extent that the load required to compress the test specimen to 50 percent of its thickness before test be not more than 1200 psi

Table 2401.3-7 Compressive Strength for Polystyrene Elements* Type Compressive Strength (minimum) [5 percent deflection] Characteristics A (High Density) 30 psi Closed Cell Expanded Polystyrene B (Low Density) 10 psi Molded Polystyrene * Test for compressive strength of polystyrene in accordance with ASTM D1621, Standard Test Method for Compressive Properties of Rigid Cellular Plastics. Furnish evidence that the Material meets these requirements, if requested by the Engineer.

Seal construction joints and saw cuts in the deck, curb face, Sidewalk, and median with a concrete joint sealer listed on the APL, Bridge, “Bridge Silicone Joint Sealants,” or in accordance with 3723, “Hot-Poured, Elastic Type Joint And Crack Sealer,” or 3725, “Hot-Poured, Extra-Low Modulus, Elastic Type Joint and Crack Sealer.” I.2 Crack Sealing The Contractor is fully responsible for crack sealing cracks identified by the Engineer in accordance with 2433, “Structure Renovation.” Where crack mapping activities of 2433.3C.3, “Seal Cracks with Epoxy by Chase Method,” require MMA flood Sealing in accordance with 2433.3C.5, “Methyl Methacrylate

Department will share in the increased cost of MMA flood seal application by executing a Change Order to compensate the Contractor at a rate equal to $0.60 per square foot of concrete area sealed by MMA Flood Seal (methyl methacrylate). The compensation rate is compensation in full for all costs of furnishing and applying the sealer including surface preparation, traffic control, and all incidentals thereto.

2401.4METHOD OF MEASUREMENT

The Engineer will separately calculate each grade or mix of structural concrete based on the dimensions shown on the Plans. The Engineer will not deduct for the volumes of concrete displaced by metal reinforcement, structural steel sections, floor drains, conduits, pile headers, chamfer strips with side dimensions no greater than 2 inches, or for variations in camber and deflections as shown on the P lans. The Engineer will not increase concrete quantity measurements for extra concrete used to secure true conformity of the elevation profile and cross-section in the finished Roadway slab as shown on the Plans. The Engineer will consider deck thickness as the thickness shown on the Plans as the minimum thickness, unless the Plans show other dimensions. The Engineer will not include concrete for keyways in quantity computations. The Engineer will measure median barrier concrete by length based on the end-to-end slab dimensions. The Engineer will measure concrete barriers by length based on the horizontal length between the outside end faces of barriers. The Engineer will measure concrete bases for metal railing based on the horizontal lengths between the outside faces of the end posts. The Department will classify the excavation in accordance with 2451.3B.2, “Types,” and the Engineer will measure the excavation in accordance with 2451.4A, “Structure Excavation,” for cast-in-place Structures. The Engineer will measure structural concrete by volume based on the dimensions of each element shown in the Plans. The Engineer will not deduct the volume due to rustication, chamfers, or other miscellaneous appurtenances. The Engineer will measure Bridge Slab structural concrete by volume based on dimensions of the Structure shown in the Plans of the slab.

The Engineer will measure reinforcement bars in conformance with 2472.4A, “Reinforcement Bars.” The Engineer will measure steel fabric in conformance with 2472.4B, “Welded Wire Reinforcing.” The Engineer will measure spiral reinforcement in conformance with 2472.4C, “Spiral Reinforcement.” The Engineer will measure the Bridge Slab by surface area based on the dimensions shown on the Plans. The Engineer will not deduct the surface area of expansion devices or other miscellaneous appurtenances. The Engineer will measure Sidewalk concrete by area based on the end-to-end Bridge dimension along the centerline of the Sidewalk and the overall width of the Sidewalk block. The Engineer will measure raised median concrete by area based on the end-to-end slab dimension and overall width of the median.

2401.5BASIS OF PAYMENT

The Contract Unit Price for structural concrete of each grade mix includes the cost of constructing the Bridge Structure complete in place, except for costs with a separate Contract Unit Price as shown on the Plans. If the Contractor elects to pour the concrete end diaphragms with the B ridge Slab, using the same concrete mix for the diaphragms as used for the slab, the Department will pay the Contract bid price for end diaphragm concrete. The Contract pound prices for reinforcement bars, steel fabric, and spiral reinforcement includes the costs of providing, fabricating, delivering, and placing the metal reinforcement . The Department will pay for structure excavation, soil bearing tests, and backfill Materials in accordance with 2451.5, “Structure Excavations and Backfills, Basis of Payment.” The Department Contract Unit Price for the relevant concrete Bridge construction Contract Item includes the cost of providing and placing joint sealer, crack sealer, and special surface finish. A Monetary Adjustments The Department must apply Incentives and Disincentives and may apply monetary deductions for Concrete Bridge Construction. The amounts of these adjustments are deemed reasonable. A.1 JMF Acceptance The Department may assess a monetary deduction for the quantity of Bridge deck concrete represented by the JMF working range failure of 2401.2K.8, “Job Mix Formula,” from the failing test to the next passing test, at a minimum rate of $500.00 or $5.00 per cubic yard, whichever is greater. A.2 Concrete Curing and Protection The Department may apply a monetary deduction for defective concrete sections in accordance with 1503, “Conformity with Contract Documents.” as directed by the Engineer. Failure to place the wet curing on Bridge Structural Slabs and Bridge Deck Slabs within 30 minutes after final strike-off of the concrete surface will constitute a Department monetary deduction of $500 for every 5 minute period, or any portion thereof, after the initial time period until the wet curing is approved by the Engineer, the Department may assess the deduction more than once.

If the Contractor fails to meet the requirements of 2401.3G.6.b, “Curing Method.” the Department may apply a monetary deduction for the concrete item in accordance with 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” A.3 Special Surface Finish For any batch/lot that does not test in compliance with 3501, “ Basic Requirements for Paint,” the Department may apply monetary deduction. Since the Contract does not contain a separate Contract Unit Price for SSF II, the Department may apply monetary deductions per the following Table 2401.5-1. The square foot measurement is calculated by the surface area of concrete element to which the non-compliant Material is placed. Table 2401.5-1 Deviation of Sample Color from Accepted Standard Deviation Monetary Deduction Δ E ≤ 3 No monetary deduction for SSF II Materials placed as approved by the Engineer. Δ E > 3 to 4 $0.15 per square foot of failing batch/lot Material placed. Δ E > 4 to 5 $0.25 per square foot of failing batch/lot Material placed. Δ E > 5 to 6 $0.40 per square foot of failing batch/lot Material placed. Δ E > 6 The Department will not apply monetary deduction. Recoat the failing surface with smooth textured SSF II product in the color specified, at no cost to the Department until Δ E ≤ 3. B Schedule The Department will pay for concrete Bridge construction on the basis of the following schedule: Item No. Item Unit

2401.503 Type ___ Barrier Concrete (Mix No.) linear foot

3 ___ Median Barrier Concrete (Mix No.) linear foot

7 Structure Excavation Class ___ cubic yard

7 Structural Concrete (Mix No.) cubic yard

7 Bridge Slab Concrete (Mix No.) cubic yard

8 Reinforcement Bars ___ pound

8 Spiral Reinforcement pound

8 Steel Fabric ___ pound

2401.518 Bridge Slab Concrete (Mix No.) square foot

8 Sidewalk Concrete (Mix No.) square foot

8 Raised Median Concrete (Mix No.) square foot

8 Structural Median Concrete (Mix No.) square foot