804Concrete Bridges and Structures

804.01 Description. This work consists of constructing concrete bridges and structures

in accordance with these specifications and in reasonably close conformity with the dimensions, designs, lines, and grades indicated on the plans or established. Construction of box bridges shall be in accordance with Sections 601 and 602.

804.02 Materials.

804.02.1 General. Concrete produced and controlled from this specification shall be

accepted upon proper certification of concre te production through an approved quality control program and verification by job site acceptance criteria. The Contractor shall develop and implement a quality control program that shall be used to maintain the required properties of concrete. For projec ts with 1000 cubic yards and more, quality control and acceptance shall be achieved through statistical evaluation of test results. For projects of more than 200 but less than 1000 cubic yards, quality control and acceptance shall be achieved by individual test results. For projects less than or equal to 200 cubic yards, refer to the requirements of TMD-20-05-00-000 “Sampling and Testing of Small Quantities of Miscellaneous Materials” for mixture design and testing requirements. The materials for concrete bridges and structures, when sampled and tested in accordance with Subsection 700.03, shall meet the requirements of the following Subsections: Cement ....................................................................................... 701.01 and 701.02 Blended Cement ......................................................................... 701.01 and 701.04 Admixtures .................................................................................................... 713.02 Fly Ash .......................................................................................................... 714.05 Ground Granulated Blast Furnace Slag (GGBFS) ......................................... 714.06 Silica Fume ................................................................................................. 714.09.2 Water .................................................................................... 714.01.1 and 714.01.2 Fine Aggregate .............................................................................................. 703.02 Coarse Aggregate .......................................................................................... 703.03 Lightweight Aggregate .................................................................................. 703.19 Curing Materials ............................................................................................ 713.01 Joint Materials ............................................................. 707.01, 707.02, and 707.07 Structural Steel Joints and Bearing Devices .................................................. 717.01 Bearing Pads .................................................................................................. 714.10 Wire Rope or Wire Cable for Prestressed Concrete ................... 711.01 and 711.03 Sprayed Finish for Concrete Surface ............................................................. 714.12 Reinforcing Steel ........................................................................................... 711.02

804.02.2 Use, Care, and Handling. The use, care, and handling of materials shall

conform to the applicable requirements of Subsection 501.03.10 and the specific requirements of Subsections 804.02.4 and 804.02.5. Unless otherwise authorized, only fine aggregate or coarse aggregate of one type and from the same source shall be used in the construction of any one unit of a structure. Should the Contractor, with written permission of the Engineer, elect to substitute high early strength cement for cement of the type specified, the Contractor will not receive additional compensation for the substitution.

804.02.3 Non-Quality Control / Quality Assurance Concrete. The following concrete

items will not be accepted based on the Qu ality Control / Quality Assurance (QC/QA) requirements. The acceptance of these conc rete items will be based on sampling and testing at the project site by Department personnel. The Contractor is required to submit mix designs to accomplish this work in accor dance with Section 804 and perform normal Quality Control functions at the concrete plant. Acceptance will be in accordance with the requirements of Section 601, Structural Concrete, and TMD-20-04-00-000. At the discretion of the Engineer, the Contractor may request that the concrete be accepted based on QC/QA requirements. Section Description 221 Paved Ditches 601 Minor Structures - manholes, inlets, catch basins, junction boxes, pipe headwalls, and pipe collars. 605 Edge Drain and Underdrain Outlet Pads 606 Guardrail Anchors 607 Fence Post Footings 608 Sidewalks 609 Curb and Gutter 614 Driveways 616 Median and Island Pavement 630 Sign Footings, except Overhead Sign Supports 815 Slope Paving

804.02.4 Care and Storage of Concrete Aggregates. The handling and storage of

aggregates shall be such as to prevent segregation or contamination with foreign materials. The Engineer may require that aggregates be stored on separate platforms at satisfactory locations. If specified, coarse aggregates shall be separated into two or more sizes in order to secure greater uniformity of the concrete mixture. Different sizes of aggregate shall be stored in separate stock piles sufficiently removed fro m each other to prevent the material at the edges of the piles from becoming intermixed.

804.02.5 Storage of Cementitious Materials. All cementitious materials shall be stored

in suitable weather-proof buildings or bins. These buildings or bins shall be placed in locations approved by the Engineer. Provision for storage shall be ample, and the shipments of cementitious materials as recei ved shall be stored separately or other provisions made to the satisf action of the Engineer for eas y access for the identification, inspection, and sampling of each shipment as deemed desirable. Stored cementitious materials shall meet the test requirements at any time after storage when a retest is ordered by the Engineer. On small jobs, open storage consisting of a raised platform and ample waterproof covering may be permitted by written authorization from the Engineer. When specified, the Contractor shall keep a ccurate records of deliveries of cementitious materials and of their use in the work. Copies of these records shall be supplied in the form required by the Engineer.

804.02.6 Classification and Uses of Concrete. When a specific class of concrete is not

specified on the plans or in the contract docu ments, the structure or parts thereof shall be constructed with the class of concrete as directed by the Engineer. The classes and their uses are as follows:

804.02.7 Blank.

804.02.8 Laboratory Accreditation. The Contractor shall be responsible for furnishing

the laboratory used to perform concrete quality control tests. The laboratory may be the Contractor’s facility, the concrete producer’s facility, or a certified independent testing laboratory. Only laboratories certified by the Department ar e qualified to perform material testing. Certification by AASHTO Accreditation Pr ogram (AAP) will be acceptable if the laboratory is listed in the latest AAP publication and maintains accreditation to completion of concrete work. The Contractor’s laboratory designated for quality control testing shall have equipment necessary to test aggregates and concrete for the test methods listed in Table 1. Table 1 AASHTO: R 39 Making and Curing Concrete Test Specimens in the Laboratory AASHTO: R 60 Sampling Freshly Mixed Concrete AASHTO: T 2 Sampling Aggregates AASHTO: T 19 Bulk Density (“Unit Weight”) and Voids in Aggregates AASHTO: T 22 Compressive Strength of Cylindrical Concrete Specimens AASHTO: T 23 Making and Curing Concrete Test Specimens in the Field AASHTO: T 27 Sieve Analysis of Fine and Coarse Aggregates AASHTO: T 84 Specific Gravity and Absorption of Fine Aggregate AASHTO: T 85 Specific Gravity and Absorption of Coarse Aggregate AASHTO: T 119 Slump of Hydraulic Cement Concrete AASHTO: T 121 Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete AASHTO: T 152 Air Content of Freshly Mixed Concrete by Pressure Method * AASHTO: T 196 Air Content of Freshly Mixed Concrete by the Volumetric Method * AASHTO: T 231 Capping Cylindrical Concrete Specimens AASHTO: T 248 Reducing Field Samples of Aggregate to Testing Size AASHTO: T 255 Total Evaporable Moistu re Content of Aggregate by Drying AASHTO: T 325 Standard Method of Test for Estimating the Strength of Concrete in Transportation Construction by Maturity Tests ** AASHTO: T 309 Temperature of Freshly Mixed Portland Cement Concrete ASTM: C 1074 Standard Practice for Estimating Concrete Strength by the Maturity Method ** * Equipment necessary for either pressure or volumetric air content. ** Equipment necessary for estimating concrete strength following the maturity method. Testing equipment shall be inspected by the Department or through the AASHTO Accreditation Program. Testing equipment calibration files shall be made available upon request by the Department.

804.02.9 Testing Personnel. Technicians testing hydraulic cement concrete, for either

acceptance or production control purposes, shall be certified by an accepted certification program. Recertification is required for each Class after five years. Certification requirements are listed in Table 2. Table 2 Concrete Technician’s Tasks Test Method Required Certification Required** Sampling or Testing of Plastic Concrete AASHTO R 60, T 23, T 119, T 121, T 152, T 196, and T 309 MDOT Class I certification Compressive Strength Testing of Concrete Cylinders AASHTO T 22 and T 231 MDOT Concrete Strength Testing Technician certification Sampling of Aggregates AASHTO T 2 Work under the supervision of a MDOT Class II certified technician Testing of Aggregates AASHTO T 19, T 27, T 84, T 85, T 248, and T 255 MDOT Class II certification Proportioning of Concrete Mixtures* AASHTO M 157 and R 39 MDOT Class III certification Interpretation and Application of Maturity Meter Readings AASHTO T 325 and ASTM C 1074 Two hours maturity method training * Technicians making concrete test sp ecimens for meeting the requirements of Subsection 804.02.10.1.2 shall be MDOT Class I certified and under the direct supervision of an MDOT Class III certified technician. ** MDOT Class I certification encompasses th e same test procedures and specifications as ACI Concrete Field Testing Technician-Grade I. MDOT Class II certification encompasses the same test procedures and specifications as ACI Aggregate Testing Technician-Level 1. MDOT Concrete Strength Testing Technician encompasses the same test procedures and specifications as ACI Concrete Strength Testing certification. Specific requirements for each level of certifica tion are in the latest edition of the Department’s Concrete Field Manual. Current MDOT Class I, MDOT Class II, and/or MDOT Class III certifications shall be acceptable until those certifications expire. Upon expiration of a current certification, recertification with the certifications listed in Table 2 shall be required. Technicians performing either specific gravity testing of aggregates or compressive strength tests shall be required to either:

804.02.10 Hydraulic Cement Concrete Mixture Design. At least 10 working days prior

to production of concrete, the Contractor shall submit to the Engineer proposed concrete mixture designs complying with the Department’s Concrete Field Manual. Materials shall be from approved sources meeting the requirements of the Standard Specifications. Proportions for the mixture designs shall be for the class concrete required by the plans and shall meet the requirements of the “Master Proportion Table for Structural Concrete Design” listed in Table 3. The concrete producer shall assign a permanent unique mixture number to each mixture design. Each mixture design shall be field verified as required in Subsection 804.02.10.3. Acceptable field verification data shall be required for final approval of a mixture design. All concrete mixture designs will be reviewed by the Materials Division prior to use. Concrete mixture designs disapproved will be returned to the Contractor with a statement explaining the disapproval. If the Contractor chooses to cure the concrete in accordance with the requirements listed under Length of Time Defined by Development of Compressive Strength in Subsection

804.03 17, the compressive strength/maturity relationship shall be developed for the

mixture design for a minimum of 28 days following the requirements of Subsection

804.03.15 The compressive strength/maturity relationship information shall be submitted

with the mixture design information. Table 3 MASTER PROPORTION TABLE FOR STRUCTURAL CONCRETE DESIGN Class Application Coarse Aggregate Size No. Maximum w/cm Ratio Specified Compressive Strength (f' c ) psi Maximum Permitted Slump, or Slump Flow inches Nominal Total Air Content (%) Maximum Static Segregation (%) AA General and Structural 57 or 67 0.45 4000 3 [-1.5] 4-8 [-2.5] 4.5±1.5 N/A B Minor Structures 57 or 67 0.50 3500 4-8 [-2.5] 4.5±1.5 N/A BD Bridge Deck 57 or 67 0.43-0.45 4000 5 [-2.5] 4.5±1.5 6.5±1.5 N/A C Massive sections 57 or 67 0.55 3000 4-8 [-2.5] 4.5±1.5 N/A D Massive unreinforced sections 57 or 67 0.70 2000 4-8 [-2.5] 4.5±1.5 N/A F 2 Prestressed members 67 0.40 5000 3 [-1.5] 4-8 [-2.5] See note NA F Prestressed members SCC 67 0.40 5000 28 [-4] See note FX Extra strength for prestressed members As per mixture design As shown on plans 3 [-1.5] 4-8 [-2.5] See note NA FX Extra strength for prestressed members As per mixture design As shown on plans 28 [-4] See note S Seal concrete deposited under water 57 or 67 0.45 3000 8 [-2.5] 4.5±1.5 N/A DS Drilled shaft 67 0.45 4000 8±1 See note N/A DS Drilled shaft SCC 67 0.45 4000 24 [-6] See note For Class BD concrete for bridge decks, the water/cementitious material ratio range shall be 0.43-0.45 and the maximum cementitious material content shall be 550 pounds per cubic yard. Also, an approved synthetic structural fiber meeting the requirements of Subsection 711.04 shall be incorporated into the mixture at 1.25 times the approved dosage rate. For each additional pound of fibers per cubic yard added in excess of the requirement stated above, an additional inch of slump will be allowed up to a maximum permitted slump of eight (8) inches. Entrained air is not required for Class F, FX, and DS concrete unless exposed to seawater. For concrete not exposed to seawater, the total air content shall not exceed 6.0%. For concrete exposed to seawater, the nominal total air content shall be 4.5%. Note: Brackets [#] indicate minus slump tolerances. The design slump selected by the Contractor for the mix design approval is the maximum slump permitted. Lightweight aggregate (LWA) meeting the requirements of Subsection 703.19.2 may also be used as a partial replacement for fine aggregate. The replacement limits of hydraulic cement by weight by other cementitious materials (such as fly ash, GGBFS, silica fume, or others) shall be in accordance with the values in Subsection 701.02. Other hydraulic cements may be used in accordance with the specifications listed in Section 701 At least one water-reducing admixture or water-reducing/set-retarding admixture shall be used in all classes of concrete in accordance with the manufacturer’s recommended dosage range. Admixtures providing a specific performance characteristic other than those of water reduction or set retardation may be used in accordance with the manufacturer’s recommended dosage range. Accelerating admixtures shall not be used unless approved by the State Materials Engineer. Any combinations of admixtures shall be approved by the Engineer before their use.

804.02.10 1--Proportioning of Hydraulic Cement Concrete Mixture Design.

Proportioning of hydraulic cement concrete shall be based on an existing mixture of which the producer has field experience and documentation or based on a recently batched laboratory mixture tested according to the required specifications.

804.02.10 1.1--Proportioning on the Basis of Previous Field Experience of Trial

Mixtures. Where a concrete production facility has a record, based on at least 10 consecutive strength tests from at least 10 different batches within the past 12 months from a mixture not previously used on Department projects, the standard deviation shall be calculated. The record of tests from which the standard deviation is calculated shall:

804.02.10 1.2 shall govern.

The required average compressive strength (f’ cr) used as the basis for selection of concrete proportions shall conform to the inequality listed below, while using a standard deviation, s, calculated as shown above. X ≥ f’ cr where: f’ cr = f’ c + 1.43s where: f’ c = specified compressive strength of concrete, psi f’ cr = required average compressive strength of concrete, psi s = standard deviation, psi 1.43 represents the Lower Quality Index necessary to assure that 93% of compressive strength tests are above f’ c.

804.02.10 1.2--Proportioning on the Basis of Laboratory Trial Mixtures. When an

acceptable record of field test results is not available, concrete proportions shall be established based on laboratory trial mixtures meeting the following restrictions:

804.02.10 2--Documentation of Average Strength. Documentation that the proposed

concrete proportions will produce an average strength equal to or greater than the required average shall consist of the strength test records from field tests or results from laboratory trial mixtures.

804.02.10 3--Field Verification of Concrete Mixture Design. Concrete mixture designs

will only be tentatively reviewed pending field verification submission and are not approved for payment by the Department until field verification is submitted. The requirements for yield, slump, or total air content shall be successfully met within the first three (3) production days. Mixture designs may be transferred to other projects without additional field verification testing if the mixture design is less than twelve (12) months old, once the mixture design has passed the field verification process. All concrete mixtures will have a complete field verification performed and submitted to the Department’s Materials Division every 12 months. The Contractor’s Certified Quality Control Technicians shall test each concrete mixture design upon the first placement of the mix. Aggregates and concrete tests during the first placement shall be as follows. Aggregates Concrete Bulk Specific Gravity Water Content Moisture Slump or Slump Flow Gradation Air Content Unit Weight Yield Static Segregation For all Classes of concrete, the mixture shall be verified to yield within 2.0% of the correct volume when all the mix water is added to the batch. For concrete categorized as a SCC mixture, the mixture shall produce a slump flow within minus four inches (4”) of the maximum permitted and a static segregation less than 15.0%. For all Classes of concrete other than DS, F, and FX, the mixture shall produce a slump within a minus 1½-inch tolerance of the design for mixtures with a design slump of three inches (3") or less or within a minus 2½-inch tolerance of the design for mixtures with a design slump of greater than three inches (3"), and producing a total air content tolerance within the maximum allowable air content in Table 3. For Class DS, the slump range shall be 8 inches ±1 inch. For Class DS exposed to seawater, the total air content shall be within the tolerance of the maximum allowable air content in Table 3. For Class DS not exposed to seawater the total air content shall be within the requirements in Table 3. For Classes F and FX, the slump shall be within a minus 1½-inch tolerance of the design for mixtures with a design slump of three inches (3") or less or within a minus 2½-inch tolerance of the design for mixtures with a design slump of greater than three inches (3"). For Classes F and FX exposed to seawater, the total air content shall be within the tolerance of the maximum allowable air content in Table 3. For Classes F and FX not exposed to seawater the total air content shall be within the requirements in Table 3. The mixture shall be adjusted and retested, if necessary, on subsequent placements until the above mentioned properties are met. If the requirements for yield, slump, or total air content are not met within the first three

804.02.10 3.1--Slump Loss of Class DS Concrete Mixture Designs. Prior to concrete

placement, the Contractor shall provide test results of a slump loss test using approved methods to demonstrate that the mixture meets the four hour requirement in Subsection

803.03.2 7.1. The Contractor shall notify the Department 48 hours prior to performing the

slump loss test. These tests shall be conducted successfully by an approved testing laboratory during the installation of the trial shaft, with personnel from the Department present. As an alternative, the slump loss test can be performed prior to the installation of the trial shaft. The slump loss test shall be conducted at temperatures and conditions similar to those expected at the job site at the time of the installation of the trial shaft. The sample for the slump loss test shall be from a minimum batch size of four (4) cubic yards of concrete. If the temperature between a successful slump loss test and the installation of the production shaft exceeds 10ºF above the concrete temperature, another successful slump loss test shall be performed on the first truckload of concrete as part of the installation of the trial shaft. The requirement to limit the time between the previous slump loss test and an installation of the trial shaft also applies to Class DS concrete mixture designs being transferred from another project. During any shaft installation a slump loss test shall be conducted by the Contractor at the direction of the Engineer from the concrete at the site for verification of slump loss requirements using a sample from a minimum batch size of four cubic yards of concrete. For concrete categorized as a SCC mixture, the Class DS SCC mixture shall not require a slump loss test.

804.02.10 4--Adjustments of Mixtures. The mixture design may be adjusted by the Class

III Certified Technician representing the Contractor in accordance with the allowable revisions listed in paragraph 5.7 of the Department’s Concrete Field Manual. Written notification shall be submitted to the Engineer a minimum of seven (7) days prior to any source or brand of material change, aggregate size change, allowable material type change, or decrease in any cementitious material content. Any adjustments of the concrete mixture design shall necessitate repeat of field verification procedure as described in Subsection

804.02.10 3.1 and approval by the Engineer.

804.02.11 Concrete Batch Plants. The concrete batch plant shall meet the requirements

of the National Ready Mixed Concrete Association Quality Control Manual, Section 3, Plant Certification Checklist as outlined in the latest edition of the Department’s Concrete Field Manual. The Contractor shall submit a copy of the approved checklist along with proof of calibration of batching equipment, i.e., scales, water meter, and admixture dispenser, to the Engineer 30 days prior to the production of concrete. For projects with 1000 cubic yards and more, the concrete batch plant shall meet the requirements for an automatic system capable of recording batch weights. It shall also have automatic moisture compensation for the fine aggregate. For projects of more than 200 but less than 1000 cubic yards the plant can be equipped for manual batching with a fine aggregate moisture meter visible to the plant operator. The concrete batch plant shall have available adequate facilities to cool concrete during hot weather. Mixer trucks to be used on the project are to be listed in the checklist and shall meet the requirements of the checklist.

804.02.12 Contractor’s Quality Control. The Contractor shall provide and maintain a

quality control program that will provide assurance that all materials and products submitted to the Department for acceptance will conform to the contract requirements, whether manufactured or processed by the Contractor or procured from suppliers, subcontractors, or vendors. The Contractor's Quality Control program shall implement the minimum quality control requirements shown in Table 4, "CONTRACTOR’S MINIMUM REQUIREMENTS FOR QUALITY CONTROL”. The quality control activities shown in the table are considered to be normal activities necessary to control the production and placing of a given product or material at an acceptable quality level. To facilitate the Department’s activities, all completed gradation samples shall be retained for a maximum of sixty (60) days by the Contractor until further disposition is designated by the Department. The Contractor shall perform, or have performed, the tests required to substantiate product conformance to contract document requirements and shall also perform, or have performed, all tests otherwise required. The Contractor’s Quality Control program shall encompass the requirements of AASHTO M 157 into concrete production and control, equipment requirements, testing, and batch ticket information. The requirement of AASHTO M 157, Section 11.7 shall be followed except, on arrival to the job site, a maximum of 1½ gallons per cubic yard shall be allowed to be added. Water shall not be added at a later time. Job site adjustment of a batch using chemical admixtures or the mechanical adjustment of a batch may be performed by the Contractor if the requirements of Subsection 804.02.12.1.1 have been satisfactorily addressed in the Quality Control Plan. If either the maximum permitted slump is exceeded or the total air content is not within the required range after all adjustments are made at the job site, the concrete shall be rejected. The Contractor's quality control tests shall be documented and shall be available for review by the Engineer throughout the life of the contract. As set out in these specifications, quality control sampling and testing performed by the Contractor will be used by the Department for determination of acceptability of the concrete. The Contractor shall maintain standard equipment and qualified personnel as required to assure conformance to contract requirements.

804.02.12 1--Quality Control Plan. The Contractor shall prepare a Quality Control Plan

that identifies the personnel responsible for the Contractor’s quality control including the company official who will act as liaison with Department personnel. The Quality Control Plan shall be submitted in writing to the Engineer for approval 30 days prior to the production of concrete. The class(es) of concrete involved will be listed separately. If an existing mixture design(s) is to be used, the mixture design number(s) as previously approved shall be listed. It is intended that sampling and testing be in accordance with standard methods and procedures, and that measuring and testing equipment be standard and properly calibrated. If alternative sampling methods and procedures and alternative inspection equipment are to be used, they shall be detailed in the Quality Control Plan.

804.02.12 1.1--Elements of Plan. The Plan shall address all elements that affect the

quality of the structural concrete including, but not limited to, the following items:

804.02.12 2--Personnel Requirements. The Contractor’s Designated Certified

Technician shall perform and use quality control tests and other quality control practices to assure that delivered materials and proportioning meet the requirements of the mixture design including temperature, slump, air content, and strength and shall periodically inspect all equipment used in transporting, proportioning, and mixing. The Contractor’s Designated Technician shall periodically inspect all equipment used placing, consolidating, finishing, and curing to assure it is operating properly and that placement, consolidation, finishing, and curing conform to the mixture design and other contract requirements.

804.02.12 3--Documentation. The Contractor shall maintain adequate records of all

inspections and tests. The records shall indicate the nature and number of observations made, the number and type of deficiencies found, date and time of samples taken, the quantities approved and rejected, and the nature of corrective action taken as appropriate. The Contractor's documentation procedures will be subject to approval of the Department prior to the start of the work and to compliance checks during the progress of the work. All conforming and non-conforming results shall be kept complete and shall be available at all times to the Department during the performance of the work. Forms shall be on a computer-acceptable medium. Batch tickets and gradation data shall be documented in accordance with Department requirements. Batch tickets shall contain all the information in AASHTO M157, Section 16, including the additional information in Subsection 16.2 with the following exception: the information listed in paragraphs 16.2.7 and 16.2.8 is not required. All material added to a batch by both the batch plant or added manually shall be documented on the ticket. Batch tickets shall also contain the concrete producer’s permanent unique mixture number assigned to the concrete mixture design. Copies shall be submitted to the Department as the work progresses. Test data for concrete, including gradation, shall be charted in accordance with the applicable requirements. The Contractor may use additional control charts as deemed appropriate. It is normally expected that testing and charting will be completed within 24 hours after sampling. All records documenting the Contractor's quality control tests shall become the property of the Department upon completion of the work.

804.02.12 4--Corrective Action. The Contractor shall take prompt action to correct

conditions that have resulted, or could result, in the submission to the Department of materials and products that do not conform to the requirements of the contract documents. All corrective actions shall be documented.

804.02.12 5--Non-Conforming Materials. The Contractor shall establish and maintain an

effective and positive system for controlling non-conforming material, including procedures for its identification, isolation and disposition. Reclaiming or reworking of non-conforming materials shall be in accordance with procedures acceptable to the Department. All non-conforming materials and products shall be positively identified to prevent use, shipment, and intermingling with conforming materials and products. Holding areas, mutually agreeable to the Department and the Contractor, shall be provided by the Contractor. TABLE 4 CONTRACTOR’S MINIMUM REQUIREMENTS FOR QUALITY CONTROL Hydraulic Cement Concrete Control Requirement Frequency AASHTO/ASTM

804.02.13 Quality Assurance Sampling and Testing. Quality Assurance (QA)

inspection and testing will be provided by the Department to assure that the Contractor’s Quality Control (QC) testing meets the requirements of these specifications. Acceptance of the material is based on the inspection of the construction, monitoring of the Contractor's QC program, QC and QA test results per Subsection 804.02.13.1, and the comparison of the QA test results with the QC test results. The Department may use the results of the Contractor’s QC tests as a part of the acceptance procedures instead of the results of QA tests, provided:

804.02.13 1--Job Control Testing.

804.02.13 1.1--Sampling. Sampling of concrete mixture shall be performed in accordance

with the latest edition of the Department’s Concrete Field Manual.

804.02.13 1.2--Slump. Slump of plastic concrete shall meet the requirements of Table 3.

A check test shall be made on another portion of the sample before rejection of any load.

804.02.13 1.3--Air. Total air content of concrete shall be within the specified range for

the class of concrete listed in Table 3. A check test shall be made on another portion of the sample before rejection of any load.

804.02.13 1.4--Yield. If the yield of the concrete mix design is more than plus or minus

three percent (±3%) of the designed volume, the mix shall be adjusted by a Class III Certified Technician representing the Contractor to yield the correct volume plus or minus three percent (±3%). If batching of the proportions of the mixture design varies outside the batching tolerance range of the originally approved proportions by more than the tolerances allowed in Subsection 804.02.12, the new proportions shall be field verified per Subsection 804.02.10.3.

804.02.13 1.5--Temperature. Cold weather concreting shall follow the requirements of

Subsection 804.03.16.1. Hot weather concreting shall follow the requirements of Subsection 804.03.16.2. Concrete with a temperature more than the maximum allowable temperature shall be rejected and not used in Department work. The maximum acceptance temperature for Class DS concrete mixtures is 95°F. The maximum acceptance temperature of Class C concrete mixtures is 100°F for mixtures meeting the cement replacement requirements of Subsection 701.02.2. For Class C concrete mixtures that do not meet the cement replacement requirements of Subsection

701.02 2, the maximum acceptance temperature is 95°F.

The maximum acceptance temperature for all other concrete mixtures meeting the cement replacement requirements of Subsection 701.02.2 is 95°F. The maximum acceptance temperature for all other concrete mixtures that do not meet the cement replacement requirements of Subsection 701.02.2 is 90°F.

804.02.13 1.6--Compressive Strength. Standard cured concrete compressive strength

tests shall conform to the specified strength (f’ c) listed in the specifications. Concrete represented by compressive strength test below the specified strength (f’ c) may be removed and replaced by the Contractor. If the Contractor elects not to remove the material, it will be evaluated by the Department as to the adequacy for the use intended. All concrete evaluated as unsatisfactory for the intended use shall be removed and replaced by the Contractor at no additional cost to the Department. For concrete allowed to remain in place, reduction in payment will be as follows: Projects with 1000 Cubic Yards and More. When the evaluation indicates that the work may remain in place, a statistical analysis will be made of the QC and QA concrete test results. If this statistical analysis indicates that at least 93% of the material would be expected to have a compressive strength equal to or greater than the specified strength (f’ c) and 99.87% of the material would be expected to have a compressive strength of at least one standard deviation above the allowable design stress (fc), the work will be accepted. If the statistical analysis indicates that either of the two criteria is not met, the Engineer will provide for an adjustment in pay as follows for the material represented by the test result. Total Pay on Material in Question = Unit Price - (Unit Price x % Reduction) % Reduction = ( ) ( ) 100× +-′ -′ sfccf Xcf x M where: f’ c = Specified 28-day compressive strength, psi X = Individual compressive strength below f’ c, psi s = standard deviation, psi* fc = allowable design stress, psi M = pay reduction multiplier, per the Concrete Field Manual, paragraph 7.3 * Standard deviation used in the above reduction of pay formula shall be calculated from the applicable preceding compressive strengths test results plus the individual compressive strength below f’c. If below f’ c strengths occur during the project’s first ten compressive strength tests, the standard deviation shall be calculated from the first ten compressive strength tests results. Projects of More Than 200 but Less Than 1000 Cubic Yards. When the evaluation indicates that the work may remain in place, a percent reduction in pay will be assessed based on a comparison of the deficient 28-day test result to the specified strength. The Engineer will provide for an adjustment in pay as follows for the material represented by the test result. Total Pay on Material in Question = Unit Price - (Unit Price x % Reduction) % Reduction = ( ) 100× ′ -′ cf Xcf x M where: f’c = Specified 28-day compressive strength, psi X = Individual compressive strength below f’c, psi M = pay reduction multiplier, per the Concrete Field Manual, paragraph 7.3

804.02.13 1.7--Static Segregation. For concrete categorized as a SCC mixture, the static

segregation of the plastic concrete shall meet the requirements of Subsection 804.02.10.1.2. If the static segregation of the concrete mix design exceeds this requirement, the mix shall be adjusted by a Class III Certified Technician representing the Contractor to ensure a static segregation less than the maximum allowable. If batching of the proportions of the mixture design varies outside the batching tolerance range of the originally approved proportions by more than the tolerances allowed in Subsection 804.02.12.1, the new proportions shall be field verified per Subsection 804.02.10.3.

804.02.14 Dispute Resolution. Disputes over variations between the Contractor’s QC

test results and the Department’s QA test results shall be resolved at the lowest possible level using the latest edition of the Department’s Concrete Field Manual. When there are significant discrepancies between the QC test results and the QA test results, the Contractor’s QC Manager, the Project Engineer, and/or the District Materials Engineer shall look for differences in the procedures, and correct the inappropriate procedure before requesting a third party resolution. If the dispute cannot be resolved at the project or District level, the Department’s Materials Division will serve as a third party to resolve the dispute. The Materials Division’s decision shall be binding. The Contractor shall be responsible for the cost associated with the third party resolution if the final decision is such that the Department’s QA test results were correct. Likewise, the Department will be responsible for the cost when the final decision is such that the Contractor’s QC test results were correct.

804.03 Construction Requirements.

804.03.1 Measurement of Materials.

804.03.1 1--General. The accuracy for measuring materials shall be in accordance with

AASHTO M 157.

804.03.1 2--Measurement by Weighing. Except when otherwise specified or authorized,

the materials shall be measured by weighing. The apparatus provided for weighing materials shall be suitably designed and constructed for this purpose. Cementitious materials and aggregates shall be weighed separately. Cement in standard bags need not be weighed, but bulk cement and other cementitious materials shall be weighed. The mixing water shall be measured by volume or by weight. All measuring devices shall be subject to approval.

804.03.2 Blank.

804.03.3 Blank.

804.03.4 Hand Mixing. Hand mixing of concrete will not be allowed.

804.03.5 Delivery. The plant supplying concrete shall have sufficient capacity and

transporting apparatus to ensure continuous delivery at the rate required. The rate of delivery shall be such as to provide for the proper continuity in handling, placing, and furnishing of the concrete. The rate shall be such that the interval between batches shall not exceed 20 minutes. The methods of delivering and handling the concrete shall be that which will facilitate placing with minimum re-handling and without damage to the structure or the concrete.

804.03.6 Handling and Placing Concrete.

804.03.6 1--General. Prior to placing concrete, all reinforcement shall have been

accurately placed in the position shown on the plans and fastened as set out in Section 805. All sawdust, chips, and other construction debris and extraneous matter shall have been removed from the interior of the forms. Temporary struts, braces, and stays holding the forms in correct shape and alignment shall be removed when the concrete placing has reached an elevation rendering their service unnecessary. These temporary members shall be entirely removed from the forms and shall not be buried in the concrete. No concrete shall be placed until the forms and reinforcement have been inspected. Except as provided for truck mixers and truck agitators, concrete shall be placed in the forms within 30 minutes after the time that the cement is first added to the mixture. Concrete shall be placed so as to avoid segregation of materials and displacement of reinforcement. The use of troughs, chutes, and pipes over 25 feet in length for gravity conveyance of concrete to the forms will not be permitted except when authorized by the Engineer and subject to the production of quality concrete. Only approved mechanical conveyors will be permitted. Open troughs and chutes shall be metal or metal lined. The use of aluminum pipes, chutes, or other devices made of aluminum that come into direct contact with the concrete shall not be used. Where steep slopes are required, the chutes shall be equipped with baffles or be in short sections that change the direction of movement. All chutes, troughs, and pipes shall be kept clean and free from coatings of hardened concrete by thoroughly flushing with water after each run. Water used for flushing shall be discharged clear of the structure. When placing operations involve dropping the concrete more than five feet, it shall be deposited through sheet metal or other approved pipes to prevent segregation and unnecessary splashing. The pipes shall be made in sections to permit discharging and raising as the placement progresses. A non-jointed pipe may be used if sufficient openings of the proper size are provided to allow for the flow of the concrete into the shaft. As far as practicable, the pipes shall be kept full of concrete during placing, and their ends shall be kept buried in the newly placed concrete. Except as herein provided, concrete shall be placed in horizontal layers not more than 12 inches thick. When, with the Engineer's approval, less than the complete length of a layer is placed in one operation, it shall be terminated in a vertical bulkhead. Each layer shall be placed and compacted before the preceding layer has taken its initial set and shall be compacted so as to avoid the formation of a construction joint with the preceding layer. If the Department determines that there is an excessive number of projections, swells, ridges, depressions, waves, voids, holes, honeycombs, or other defects in the completed structure, removal of the entire structure may be required as set out in Subsection 105.12.

804.03.6 2--Consolidation. Immediately after depositing the concrete mixture, the

concrete mixture shall be thoroughly consolidated by the use of approved mechanical vibrators and suitable spading tools. Only concrete mixture that has not achieved initial set shall be consolidated. Hand spading alone will be permitted on small structural members such as railing, small culvert headwalls, and as necessary to ensure smooth surfaces and dense concrete along form surfaces, in corners, and in locations impossible to reach with vibrators. When hand spading is used for consolidation, a sufficient number of workmen with spading tools shall be provided. For hand spading, flush a thin layer of mortar to all the surfaces and thoroughly and satisfactorily consolidate the concrete. SCC concrete shall not be consolidated by vibration. The Contractor shall conduct operations of depositing and consolidating the concrete mixture such that the operation produces concrete that is uniformly smooth and dense, having no honeycombing or pockets of segregated aggregate. Movement of personnel through the consolidated concrete shall not be permitted. If it is determined that it is necessary to step into previously consolidated concrete, the concrete in the stepped into area shall be consolidated again.

804.03.6 2.1--Requirements for Vibrators. Mechanical vibrators shall be subject to the

following:

804.03.6 2.2--Operation of Internal Vibration. Mechanical vibrators used for internal

vibration shall be operated as follows:

804.03.6 2.3--Method of Consolidation. The Contractor will accomplish consolidation

by internal vibration using vibrators mounted on a mechanical device or an orchestrated effort utilizing personnel. Regardless of the chosen method, the method shall be included in the QCP in accordance with Subsection 804.02.12.1 and shall only receive tentative approval until the method is demonstrated as effectively meeting the requirements of Subsection 804.03.6.2.

804.03.6 3--Discontinuance of Placing. When placing is temporarily discontinued, the

concrete, after becoming firm enough to retain its form, shall be cleaned of laitance and other objectionable material to a sufficient depth to expose sound concrete. To avoid visible joints insofar as possible upon exposed faces, the top surface of the concrete adjacent to the forms shall be smoothed with a trowel. Where a "feather edge" might be produced at a construction joint, such as in the sloped top surface of a wing wall, an inset form work shall be used in the preceding layer to produce a blocked out portion that will provide an edge thickness of at least six inches (6”) in the succeeding layer. Work shall not be discontinued within 18 inches of the top of any face unless provision has been made for a coping less than 18 inches thick. In this case, and if permitted by the Engineer, the construction joint may be made at the underside of the coping. Immediately following the discontinuance of placing concrete, all accumulations of mortar splashed on the reinforcement and the surface of forms shall be removed. Dried mortar chips and dust shall not be puddled into the unset concrete. If the accumulations are not removed prior to the concrete becoming set, care shall be exercised not to break or injure the concrete-steel bond at and near the surface of the concrete while cleaning the reinforcement. After initial set the forms shall not be jarred, and no strain shall be placed on the ends of projecting reinforcement until the concrete has sufficiently set to ensure against any damage by such jarring or strain.

804.03.6 4--Placing Bridge Concrete. The method and sequence of placing concrete shall

conform to the provisions and requirements set forth for the particular type of construction.

804.03.6 4.1--Foundations and Substructures. Concrete seals shall be placed in

accordance with Subsection 804.03.9. All other concrete for foundations shall be poured in the dry unless otherwise stipulated or authorization is given in writing by the Engineer to do otherwise. Concrete shall not be placed in foundations until the foundation area has been inspected and approved. Unless otherwise specified, the placement of concrete in the substructure shall be in accordance with the general requirements of Subsection 804.03.6. Unless otherwise directed, concrete in columns shall be placed in one continuous operation, and shall be allowed to set at least 12 hours before the caps are placed.

804.03.6 4.2--Superstructure. For simple spans, concrete shall preferably be deposited

by beginning at the center of the span and working toward the ends. For continuous spans, concrete shall be deposited as shown on the plans. Concrete in girders shall be uniformly deposited for the full length of the girder and brought up evenly in horizontal layers. Concrete in areas below the bridge deck but which is deposited at the same time as concrete for the bridge deck like a diaphragm, shall be placed and consolidated sufficiently ahead of placing the concrete for the bridge deck such that the placing, consolidating, finishing, and curing of concrete for the bridge deck shall not be impeded or slowed. Unless otherwise permitted by the Engineer, concrete shall not be placed in the superstructure until the column forms have been stripped sufficiently to determine the character of the concrete in the columns. Unless otherwise permitted by the Engineer, the load of the superstructure shall not be placed on pile bents until the caps have been in place at least seven (7) days and shall not be placed on other types of bents until the bents have been in place at least 14 days. In placing concrete around steel shapes, it shall be placed on one side of the shape until it flushes up over the bottom flange of the shape on the opposite side, after which it shall be placed on both sides to completion. Concrete in girder haunches less than three feet (3’) in height shall be placed at the same time as that in the girder stem. Whenever a haunch or fillet has a height of three feet (3’) or more at the abutment or columns, the haunch and the girder shall be poured in three successive stages: (a) up to the lower side of the haunch; (2) to the lower side of the girder; and (3) to completion. Except when intermediate construction joints are specified, concrete in slab, T-beam, or deck-girder spans shall be placed in one continuous operation for each span. The floors and girders of through-girder superstructures shall be placed in one continuous operation unless otherwise specified, in which case special shear anchorage shall be provided to ensure monolithic action between girder and floor. Concrete in box girders shall be placed as shown on the plans. Concrete shall not be chuted directly into the forms of the span and shall be placed continuously with sufficient speed to be monolithic and to allow for finishing before initial set.

804.03.6 4.3--Bridge Deck. When using the Transverse Method in accordance with

Subsection 804.03.19.7.3, the period of time between concrete placement and completion of the final curing shall be kept to a minimum, as directed by the Engineer.

804.03.7 Pneumatic Placing. Pneumatic placing of concrete will be permitted only if

specified in the contract or if authorized by the Engineer. The equipment shall be so arranged that no vibrations result that might damage freshly placed concrete. Where concrete is conveyed and placed by pneumatic means, the equipment shall be suitable in kind and adequate in capacity for the work. The machine shall be located as close as practicable to the place of deposit. The position of the discharge end of the line shall not be more than 10 feet from the point of deposit. The discharge lines shall be horizontal or inclined upwards from the machine. At the conclusion of placement the entire equipment shall be thoroughly cleaned.

804.03.8 Pumping Concrete. Placement of concrete by pumping will be permitted only

if specified in the contract or if authorized in writing by the Engineer. If used, the equipment shall be arranged so that no vibrations result that might damage freshly placed concrete. Where concrete mixture is conveyed and placed by mechanically applied pressure (pumping), the equipment shall be suitable in kind and adequate in capacity for the work. The Contractor shall select concrete mixture proportions such that the concrete mixture is pumpable and placeable with the selected equipment. The pumping equipment shall be thoroughly cleaned prior to concrete placement. Excess form release agent shall be removed from the concrete pump hopper. The Contractor shall prime the pump at no additional cost to the Department by pumping and discarding enough concrete mixture to produce a uniform mixture exiting the pump. At least 0.25 cubic yard of concrete mixture shall be pumped and discarded to prime the pump. Only concrete mixture shall be added directly into the concrete pump hopper after placement has commenced. If anything other than concrete mixture is added to the concrete pump hopper, all concrete mixture in the concrete pump hopper and pump line shall be discarded and the pump re-primed at no additional cost to the Department. The discharge end of the pump shall be of such a configuration that the concrete does not move in the pump line under its own weight. The intent of this requirement is to ensure that entrained air in the concrete mixture remains entrained during pumping and depositing the concrete mixture. This shall be accomplished with one or both of the following:

804.03.9 Depositing Concrete Under Water. Concrete shall not be deposited in water

except with the approval of the Engineer. Concrete deposited under water shall be Class S. Concrete deposited under water shall be carefully placed in a compact mass in its final position by means of a tremie, a bottom dump bucket, or other approved method and shall not be disturbed after being deposited. Special care shall be exercised to maintain still water at the point of deposit. No concrete shall be placed in running water and all form work designed to retain concrete under water shall be water-tight. The consistency of the concrete shall be carefully regulated, and special care shall be exercised to prevent segregation of materials. Concrete seals shall be placed continuously from start to finish, and the surface of the concrete shall be kept as nearly horizontal as practicable at all times. To ensure thorough bonding, each succeeding layer of a seal shall be placed before the preceding layer has taken initial set. When a tremie is used, it shall consist of a tube having a diameter of at least 10 inches and constructed in sections having flanged couplings fitted with gaskets. The means of supporting the tremie shall be such as to permit the free movement of the discharge over the entire top surface of the work and to permit it to be lowered rapidly when necessary to choke off or retard the flow of concrete. The discharge end shall be closed at the start of the work so as to prevent water entering the tube and shall be entirely sealed. The tremie tube shall be kept full to the bottom of the hopper. When a batch is dumped into the hopper, the flow of concrete shall be induced by slightly raising the discharge end, always keeping it in the deposited concrete. The flow is then stopped by lowering the tremie. The flow shall be continuous until the work is completed. Depositing of concrete by the drop bottom bucket method shall conform to the following:

804.03.10 Construction Joints.

804.03.10 1--General. Unless otherwise approved by the Engineer, construction joints

shall be made only where located on the plans or shown in the pouring schedule. If not detailed on the plans, or in the case of emergency, construction joints shall be placed as directed by the Engineer. Shear keys or inclined reinforcement shall be used where necessary to transmit shear or to bond the two sections together. For continuous spans, bridge deck concrete shall be deposited as shown on the plans. Deviation from the pouring schedule shown in the plans is not permitted.

804.03.10 2--Bonding. Before depositing new concrete on or against concrete that has

hardened, the forms shall be retightened. The surface of the hardened concrete shall be roughened as required by the Engineer and in a manner that will not leave loosened particles of aggregate or damaged concrete at the surface. It shall be thoroughly cleaned of foreign matter and laitance and saturated with water. When directed by the Engineer, the cleaned and saturated surfaces, including vertical and inclined surfaces, shall first be thoroughly covered with a coating of mortar or neat cement grout against which the new concrete shall be placed before the grout has attained its initial set. The placing of concrete shall be carried continuously from joint to joint. The face edges of all joints that are exposed to view shall be carefully finished, true to line and elevation. In order to bond successive courses suitable depressed or raised keys of the designated size shall be constructed. Raised keys shall be monolithic with the concrete of the lower course.

804.03.11 Concrete Exposed to Seawater. Unless otherwise specifically provided,

concrete for structures exposed to seawater shall be Class AA concrete as referenced in Subsection 804.02.10. The clear distance from the face of the concrete to the nearest face of reinforcing steel shall be at least four inches. The mixing time and the water content shall be carefully controlled and regulated so as to produce concrete of maximum impermeability. The concrete shall be thoroughly compacted, and stone pockets shall be avoided. No construction joints shall be formed between the levels of extreme low water and extreme high water as determined by the Engineer. Between these levels, seawater shall not come in direct contact with the new concrete until at least 30 days have elapsed. The surface concrete as left by the forms shall be left undisturbed.

804.03.12 Blank.

804.03.13 Falsework. The Contractor shall submit to the Engineer four copies of

structural design analysis and detail drawings that show the method of falsework or centering. These designs and detail plans shall be prepared and bear the seal of a Registered Professional Engineer with experience in falsework design. Falsework plans shall include falsework elevations together with all other dimensions and details that are considered necessary for the construction. Other pertinent data needed is size and spacing of all falsework members and minimum bearing requirements for false piles. Upon completion of falsework erection, the Registered Professional Engineer shall certify that the erected falsework is capable of supporting the load for construction. Falsework piling shall be spaced and driven so that the bearing value of each pile is sufficient to support the load that will be imposed upon it. The bearing value of the piles should be calculated according to the appropriate formula given in Section 803. For designing falsework and centering, a weight of 150 pounds per cubic foot shall be assumed for green concrete. All falsework shall be designed and constructed to provide the necessary rigidity and to support the loads without appreciable settlement or deformation. The Contractor may be required to employ screw jacks or hardwood wedges to take up slight settlement in the falsework either before or during the placing of concrete. An allowance shall be made for anticipated compressibility of falsework and for the placement of shims, wedges, or jacks to produce the permanent structural camber shown on the plans. If during construction, any weakness develops and the falsework shows any undue settlement or distortion, the work shall be stopped, the part of the structure affected removed, and the falsework strengthened before work is resumed. Falsework that cannot be founded on a satisfactory footing shall be supported on piling, which shall be spaced, driven, and removed, as referenced in Subsection 804.03.15, in a manner approved by the Engineer. All structures built across a public street or highway on which maintenance of traffic is required, shall have falsework so arranged that a vertical clearance of at least 12' 6" is provided. Unless otherwise specified, a horizontal clearance of at least the width of the traveled way shall be provided at all times. If the vertical clearance is less than 13' 6" or the horizontal clearance is less than the full crown width of the roadway, the Contractor shall install and maintain appropriate safety devices, clearance signs and warning lights, and shall notify the Engineer sufficiently in advance of restricting the clearance for the Engineer to advise both the Traffic Engineering and the Maintenance Divisions. All traffic control and safety devices shall be in accordance with the MUTCD.

804.03.14 Forms.

804.03.14 1--General. Forms shall be wood, metal, or other material approved by the

Engineer. All forms shall be built mortar-tight and sufficiently rigid to prevent distortion due to pressure of the concrete and other loads incident to the construction operations. Forms shall be constructed and maintained so as to prevent warping and the opening of joints due to shrinkage. The forms shall be substantial and unyielding and shall be so designed that the finished concrete will conform to the proper dimensions and contours. The design of the forms shall take into account the effect of vibration of concrete as it is placed. Minimum requirements for slab overhang forms shall be 3/4-inch plywood supported on 2-inch x 6-inch S4S wood timbers placed flatwise on 16-inch centers. Adjustable brackets for support of slab overhang forms shall be spaced at a maximum distance of 3' 0" center to center unless specifically approved otherwise. Grade points for forms shall coincide with the location of the adjustable form brackets. Forms for surfaces exposed to view shall be of uniform thickness with a smooth inside surface of an approved type. Joints in forms for exposed surfaces shall be closely fitted to eliminate fins, stone pockets, or other variations in the surface of the concrete that would mar a smooth and uniform texture. Forms shall be filleted at all sharp corners and shall be given a bevel or draft in the case of all projections, such as girders and copings, to ensure easy removal. Metal ties or anchorages within the forms shall be so constructed as to permit their removal, without injury to the concrete, to a depth of at least the reinforcing steel clearance shown on the plans. In case ordinary wire ties are permitted, all wires, upon removal of the forms, shall be cut back at least 1/4 inch from the face of the concrete with chisels or nippers. Nippers shall be used for green concrete. All fittings for metal ties shall be designed so that upon their removal the cavities that are left will be the smallest practicable size. The cavities shall be filled with cement mortar and the surface left sound, smooth, even, and uniform in color. Forms shall be set and maintained to the lines designated until the concrete is sufficiently cured for form removal. Forms shall remain in place for periods determined as hereinafter specified. If forms are deemed to be unsatisfactory in any way, either before or during the placing of concrete, the Engineer will order the work stopped until the defects have been corrected. The shape, strength, rigidity, water-tightness, and surface smoothness of reused forms shall be maintained at all times. Warped or bulged lumber shall be resized before being reused. Forms that are unsatisfactory in any respect shall not be reused. Access to the lower portions of forms for narrow walls and columns shall be provided for cleaning out extraneous material immediately before placing the concrete. All forms shall be treated with an approved oil or saturated with water immediately before placing the concrete. For rail members or other members with exposed faces, the forms shall be treated only with an approved oil to prevent the adherence of concrete. Any material that will adhere to or discolor the concrete shall not be used. When metal forms are used they shall be kept free from rust, grease, or other foreign matter that will discolor the concrete. They shall be of sufficient thickness and so connected that they will remain true to shape and line, and shall conform in all respects as herein prescribed for mortar tightness, filleted corners, beveled projections, etc. They shall be constructed so as to ensure easy removal without injury to concrete. All inside bolt and rivet heads shall be countersunk. All chamfer strips shall be dressed, straight, and of uniform width and shall be maintained as such at all times.

804.03.14 2--Stay-In-Place Metal Forms. Stay-in-place (SIP) metal forms are corrugated

metal sheets permanently installed between the supporting superstructure members. After the concrete has cured, these forms shall remain in place as permanent, non-structural members of the bridge. Pay quantities for deck concrete will be computed from the dimensions shown in the contract plans with no allowance for changes in deflection and /or changes in dimensions necessary to accommodate the SIP metal forms. There will be no direct payment for the cost of the forms and form supports, or any material, tools, equipment, or labor incidental thereto, but the cost shall be considered absorbed in the contract unit price for concrete. Before fabricating any material, three (3) complete sets of SIP metal form shop drawings and design calculations, bearing the Design Engineer’s seal, shall be submitted to the Director of Structures, State Bridge Engineer, through the Engineer, for review. The Contractor’s SIP metal form Design Engineer shall be a Mississippi Registered Professional Engineer who is knowledgeable in the field of structural design. In no case shall additional dead load produced by the use of SIP metal forms overstress any bridge component. Design calculations shall indicate any additional dead load from SIP metal form self-weight, form support hangers, concrete in flutes, concrete due to form deflection, etc., that are not included in the plans. The additional dead loads shall be clearly labeled and tabulated on the shop drawings. Bridge Division will evaluate the additional load for overstress of the bridge components. In the event that the additional dead load produces an overstress in any bridge component, Bridge Division will reject the Contractor’s design. Deflection and loads produced by deflection of the SIP metal forms shall be considered and indicated in the design calculations. The cambers and deflections provided in the plans do not consider the effects of SIP metal forms. The Contractor’s Engineer shall take into account the weight of the forms and any additional dead load when developing the “Bridge Superstructure Construction Plan”. For the purpose of reducing any additional dead load produced by the SIP metal forms, the flutes of SIP metal forms may be filled with polystyrene foam. When polystyrene foam is used to fill the forms, the form flutes shall be filled completely. No portion of the polystyrene foam shall extend beyond the limits of the flutes. The Contractor shall ensure that the polystyrene foam remains in its required position within flutes during the entire concrete placement process. The Contractor shall not use reinforcing steel supports or other accessories in such a manner as to cause damage to the polystyrene foam. All damaged polystyrene foam shall be replaced to the satisfaction of the Engineer. All welding of formwork shall be completed prior to placement of polystyrene foam. For bridges not located in horizontal curves, the Contractor may reduce the additional dead load by matching the flute spacing with the transverse steel spacing of the bottom layer. The bottom longitudinal layer of steel shall have one (1) inch of minimum concrete cover measured from the bottom of the reinforcing to the top of the flute. The Contractor will not be allowed to vary the reinforcing steel spacing or size from the plans for the purpose of matching flute spacing.

804.03.14 2.1--Materials. SIP metal forms and supports shall meet the requirements of

ASTM A653 having a coating designation G165. Form materials that are less than 0.03- inch uncoated thickness shall not be allowed.

804.03.14 2.2--Certification. The Contractor shall provide written certification from the

manufacturer stating that the product meets the requirements of this specification to the Engineer along with the delivery of the coated forms to the job site.

804.03.14 2.3--Polystyrene Foam. The polystyrene foam shall be comprised of expanded

polystyrene manufactured from virgin resin of sufficient density to support the weight of concrete without deformation. The polystyrene foam shall be extruded to match the geometry of the flutes and provide a snug fit. The polystyrene foam shall have a density of not less than 0.8 pounds per cubic foot. The polystyrene foam shall have water absorption of less than 2.6% when tested according to ASTM C272. The Contractor shall provide written certification from the manufacturer stating the polystyrene foam product meets the requirements of this specification to the Engineer along with the delivery of the coated forms to the job site.

804.03.14 2.4--Design. The design of the SIP metal forms shall meet the following criteria.

804.03.14 2.5--Construction. SIP metal form sheets shall not rest directly on the top of

the stringer of floor beam flanges. Sheets shall be fastened securely to form supports, and maintain a minimum bearing length of one (1) inch at each end for metal forms. Form supports shall be placed in direct contact with the flange of the stringer or floor beam. All attachments for coated metal forms shall be made by bolts, clips, screws, or other approved means.

804.03.14 2.6--Form Galvanizing Repairs. Where forms or their installation are

unsatisfactory in the opinion of the Engineer, either before or during placement of the concrete, the Contractor shall correct the defects before proceeding with the construction work. The cost of such corrective work shall be at the sole expense of the Contractor. Minor heat discoloration in areas of welds shall not be touched up.

804.03.14 2.7--Concrete. The Contractor shall ensure concrete placement does not

damage the SIP metal forms. Approved pouring sequences shall be used. The completed SIP metal form system shall be sufficiently tight to prevent leakage of mortar or concrete. The concrete shall be consolidated to avoid honeycomb and voids, especially at construction joints, expansion joints, valleys, and ends of form sheets. Calcium chloride or any other admixture containing chloride salts shall not be used in the concrete.

804.03.14 2.8--Inspection. The Engineer will observe the Contractor’s method of

construction during all phases of the construction of the bridge deck slab, including the installation of the SIP metal form system, location and fastening of the reinforcement, composition of concrete items, mixing procedures, concrete placement, and vibration, and finishing of the bridge deck. Should the Engineer determine that the procedures used during the placement of the concrete warrant inspection of the underside of the deck, at least one section of the metal forms shall be removed in each span for this purpose. This shall be done as soon after placing the concrete as practical in order to provide visual evidence that the concrete mix and the procedures are obtaining the desired results. An additional section shall be removed in any span if the Engineer determines that there has been any change in the concrete mix or in the procedures warranting additional inspection. If, in the Engineer’s judgment, inspection is needed to check for defects in the bottom of the deck or to verify soundness, the SIP metal forms shall be sounded with a hammer after the deck concrete has been in place a minimum of two days. If sounding discloses areas of doubtful soundness to the Engineer, the SIP metal forms shall be removed from such areas for visual inspection after the concrete has attained adequate strength. The SIP metal bridge deck forms shall be removed at no expense to the State. At locations where sections of the metal forms have been removed, the Engineer will not require the Contractor to replace the metal forms. The adjacent metal forms and supports shall be repaired to present a neat appearance and to ensure their satisfactory retention. As soon as the form is removed, the Engineer will examine the concrete surfaces for cavities, honeycombing, and other defects. If irregularities are found and the Engineer determines that these irregularities do not justify rejection of the work, the concrete shall be repaired as directed by the Engineer. If the Engineer determines that the concrete where the form is removed is unsatisfactory, additional metal forms as necessary shall be removed to inspect and repair the slab, and the Contractor’s method of construction shall be modified as required to obtain satisfactory concrete in the slab. All unsatisfactory concrete shall be removed and replaced as directed at no expense to the State. If the method of construction and the results of the inspections as outlined above indicate that sound concrete has been obtained throughout the slabs, the amount of sounding and form removal may be reduced when approved by the Engineer. The Contractor shall provide a safe and convenient means of conducting the inspection.

804.03.15 Removal of Falsework, Forms, and Housing. In the determination of the

time for the removal of falsework, forms and housing and the discontinuance of heating, consideration shall be given to the location and character of the structure, the weather and other conditions influencing the setting of the concrete, and the materials used in the mix. No forms or supports shall be removed prior to approval by the Engineer. During cold weather, removal of housing and the discontinuance of heating shall be in accordance with Subsection 804.03.16.1. Concrete in the last pour of a continuous superstructure shall have attained a compressive strength of 2,400 psi, as determined by cylinder tests or maturity meter probe, prior to striking any falsework. It is important that falsework be removed as evenly as possible to prevent excessive deflection stresses in the spans. At the Contractor's option and with the approval of the Engineer, the time for removal of forms may be determined by cylinder tests, in accordance with the requirements listed in Table 6, in which case the Contractor shall furnish facilities for testing the cylinders. The facilities shall include an approved concrete testing machine of sufficient capacity and calibrated by an acceptable commercial laboratory. Tests shall be conducted in the presence of a Department representative to witness and record strengths obtained on each break or performed by a Department certified technician in an approved testing laboratory. The cylinders shall be cured under conditions that are not more favorable than those existing for the portions of the structure that they represent. Table 6 Minimum Compressive Strength Requirements for Form Removal Forms: Columns ..................................................................... 1000 psi Side of Beams ............................................................. 1000 psi Walls not under pressure ............................................ 1000 psi Floor Slabs, overhead ................................................. 2000 psi Floor Slabs, between beams ....................................... 2000 psi Slab Spans .................................................................. 2400 psi Other Parts .................................................................. 1000 psi Centering: Under Beams .............................................................. 2400 psi Under Bent Caps ........................................................ 2000 psi Limitation for Placing Beams on: Pile Bents, pile under beam ........................................ 2000 psi Frame Bents, two or more columns ............................ 2200 psi Frame Bents, single column ....................................... 2400 psi For bridges, non-SIP metal forms for bridge deck slabs overhead and bridge deck slabs between beams shall be removed with the approval of the Engineer, between two weeks and four weeks after the removal of the wet burlap applied in accordance with Subsection

804.03.17 1, or the application of liquid membrane applied in accordance with Subsection

804.03.17 2.

In lieu of using concrete strength cylinders to determine when falsework, forms, and housings can be removed, an approved maturity meter may be used to determine concrete strengths by inserting probes into concrete placed in a structure. The minimum number of maturity meter probes required for each structural component shall be in accordance with Table 7. Falsework, forms, and housings may be removed when maturity meter readings indicate that the required concrete strength is achieved. Procedures for using the maturity meter and developing the strength/maturity relationship shall follow the requirements of AASHTO T 325 and ASTM C 1074 specifications. Technicians using the maturity meter or calculating strength/maturity graphs shall be required to have at least two hours of training prior to using the maturity equipment. Table 7 Requirements for use of Maturity Meter Probes Structure Component Quantity of Concrete No. of Probes Slabs, beams, walls, & miscellaneous items 0 - 30 yd > 30 to 60 yd > 60 to 90 yd > 90 yd Footings, Columns & Caps 0 - 13 yd > 13 yd Pavement, Pavement Overlays 1200 yd Pavement Repairs Per repair or 900 yd , 2 whichever is smaller Methods of form removal likely to cause overstressing of the concrete shall not be used. Forms and supports shall be removed in a manner that will permit the concrete to uniformly and gradually take the stresses due to its own weight. Centers shall be gradually and uniformly lowered in a manner that will avoid injurious stresses in any part of the structure. As soon as concrete for railings, ornamental work, parapets and vertical faces that require a rubbed finish has attained a safe strength, the forms shall be carefully removed without marring the surfaces and corners, the required finishing performed, and the required curing continued. Prior to final inspection of the work, the Contractor shall remove all falsework, forms, excavated material or other material placed in the stream channel during construction. Falsework piles may be cut or broken off at least one foot below the mudline or ground line unless the plans specifically indicate that they are to be pulled and completely removed from the channel.

804.03.16 Cold or Hot Weather Concreting.

804.03.16 1--Cold Weather Concreting. In cold weather, the temperature of the concrete

when delivered to the job site shall conform to the temperature limitations of “Temperature Limitations on Concrete when Delivered to Job Site” listed in Table 8 below. Cold weather is defined as three consecutive days when there is a probability that the daily average of the highest and lowest ambient temperatures is expected to be less than 40°F. This three- day forecast shall be based on the latest information available from the National Weather Service. When the Contractor proposes to place concrete during seasons when there is a probability of ambient temperatures lower than 40°F, the Contractor shall have available on the project the approved facilities necessary to enclose uncured concrete and to keep the temperature of the air inside the enclosure within the ranges and for the minimum periods specified herein. When there are indications of temperatures of less than 40°F during the first four days after placement of the concrete, the concrete shall be protected from cold temperatures by maintaining a temperature between 50°F and 100°F for at least four days after placement and between 40°F and 100°F for at least three additional days. The Contractor shall use such heating equipment such as stoves, salamanders, or steam equipment as deemed necessary to protect the concrete. When dry heat is used, means of maintaining atmospheric moisture shall be provided. At the option of the Contractor with the approval of the Engineer, when concrete is placed during cold weather and there is a probability of ambient temperatures lower than 40°F, an approved maturity meter may be used to determine concrete strengths by inserting probes into concrete placed in a structure. The minimum number of maturity meter probes required for each structural component shall be in accordance with Table 7. An approved insulating blanketing material shall be used to protect the work when ambient temperatures are less than 40°F and shall remain in place until the required concrete strength in Table 6 is achieved. Procedures for using the maturity meter and developing the strength/maturity relationship shall follow the requirements of AASHTO T 325 and ASTM C 1074 specifications. Technicians using the maturity meter or calculating strength/maturity graphs shall be required to have at least two hours of training prior to using the maturity equipment. One or more of the aggregates and/or mixing water may be heated. The aggregates may be heated by steam, dry heat, or by placing in the mixing water that has been heated. Frozen aggregates shall not be used. When either aggregates or water are heated above 100°F, the aggregates and water shall be combined first in the mixer before the cement is added to avoid flash set. Cement shall not be mixed with water or with a mixture of water and aggregate having a temperature greater than 100°F. The use of salt or other chemical admixtures in lieu of heating will not be permitted. Before placing concrete, all ice or frost shall be removed from the forms and reinforcement. In the case of concrete placed directly on or in the ground, such as for footings or bottom slabs, protection and curing during cold weather may be provided as set for concrete pavement under Subsection 501.03.20.3. The Contractor shall assume all risk and added cost connected with the placing and protecting of concrete during cold weather. Permission given by the Engineer to place concrete during such time will in no way relieve the Contractor of responsibility for satisfactory results. Should it be determined at any time that the concrete placed under such conditions is unsatisfactory, it shall be removed and replaced with satisfactory concrete by the Contractor without extra compensation. TABLE 8 COLD WEATHER TEMPERATURE LIMITATIONS ON CONCRETE WHEN DELIVERED TO JOB SITE Section thickness in the least dimension inches Jobsite Acceptance Temperature Range °F Less than 12 55 to 75 12 to 36 50 to 70 36 to 72 45 to 65 Greater than 72 40 to 60

804.03.16 2--Hot Weather Concreting. The manufacture, placement, and protection of

concrete during hot weather requires special attention to ensure that uniform slump ranges and satisfactory placement qualities are maintained, that surface cracking is held to a minimum, and that design strengths are produced. For bridge decks when the ambient temperature is above 90°F, the forms, reinforcing steel, steel beam flanges, and other surfaces which will come in contact with the concrete shall be cooled to below 90°F by means of a water spray or other approved methods. Additionally, when the atmospheric temperature is predicted to be 90°F or above based on the latest information available from the National Weather Service any time during the day of placement or day after placement, the time of placement shall not begin until 5:00 p.m. on the day of placement and shall be completed by 6:00 a.m. the following day.

804.03.17 Curing Concrete. Curing is defined as all actions taken to ensure the moisture

and temperature conditions of freshly placed concrete exist so the concrete may develop strength and result in a long lasting, durable, structural member. Curing shall take place from the time of placement until the developed strength is such that the concrete is not damaged by rapid drying or temperature gradients. The Contractor shall use the guidance in ACI 308R-01 to:

804.03.17 2 shall be established within 20 minutes after finishing, except as noted for

bridge decks. Finishing is considered to be complete when the pan drag, burlap drag, or other finishing methods are complete. The required method of curing for bridge deck concrete is dependent on the method of strike-off, the type of formwork used, and whether or not lightweight aggregate (LWA) is used for internal curing. The required method of curing for each alternative is as follows:

804.03.14 2 - Stay-In-Place Metal Forms and 804.03.19.7.3 - Transverse Method.

703.19.2 and the mixture contains an internal curing water content of 8.0 pounds or greater

per 100 pounds of total cementitious materials, the bridge deck concrete may be cured in accordance with Subsection 804.03.17.1 - Water With Waterproof Cover or Subsection

804.03.17 2 - Liquid Membrane.

The length of time for curing shall be maintained on the bridge deck surface in accordance with either of the following:

804.02.10 1.

If cured following the requirements of Subsection 804.03.17.1 - Water With Waterproof Cover, once the concrete achieves 75% of the 28-day compressive the polyethylene sheeting and wet burlap may be removed and a single layer of liquid membrane applied. For bridge decks, construction traffic may utilize the deck during the 7-day drying period but the Contractor is required to immediately reapply liquid membrane to any marred surfaces.

804.03.17 1--Water with Waterproof Cover. All burlap shall be completely saturated and

wet prior to placing it on the concrete. The burlap shall have been fully soaked in water for a minimum of 12 hours prior to placement on the concrete. For bridge decks, the Contractor shall apply one (1) layer of saturated burlap within 20 minutes of the initial strike-off for bridges without a skew and 25 minutes of the initial strike- off for bridges with a skew. For all other concrete, the Contractor shall apply one (1) layer of saturated burlap within 20 minutes of completing finishing. For bridge decks, following the first layer of burlap, the Contractor shall apply a second layer of saturated burlap within five (5) minutes of applying the first layer. The applied burlap shall completely cover all exposed concrete surfaces. In areas where the burlap may not be directly applied due to the concrete surface, for example, in areas where reinforcing steel protrudes thru the concrete surface, like in the areas of a bridge deck where the bridge railing will be constructed at a later time, the saturated burlap shall be draped over the steel. The concrete surface shall not be allowed to dry after strike-off or at any time during the curing period. The Contractor shall maintain the burlap in a fully wet condition using powered fogging equipment capable of producing a fog spray of atomized droplets of water until the concrete has gained sufficient strength to allow foot traffic without the foot traffic marring the surface of the concrete. Burlap shall not be maintained in the fully wet condition using equipment that does not produce a fog spray of atomized droplets of water or by use of manually pressurized sprayers. For bridge decks, once the concrete has gained sufficient strength to allow foot traffic that does not mar the surface of the concrete, soaker hoses shall be placed on the burlap. The soaker hoses shall then be supplied with running water continuously to maintain continuous saturation of all burlap and the entire concrete surface. If there is a delay in the placement of the first layer of saturated burlap outside the time limit, the struck-off and finished concrete shall be kept wet by use of the powered fogging equipment used to keep the burlap wet. White polyethylene sheets shall be placed on top of the wet burlap and, as applicable, soaker hoses, covering the entire concrete surface as soon as practical and not more than 12 hours after the placement of the concrete. White polyethylene sheets of the widest practical width shall be used, overlapping adjacent sheets a minimum of six inches (6”) and tightly sealed with an adhesive like pressure sensitive tape, mastic, glue, or other approved methods to form a complete waterproof cover of the entire concrete surface. White polyethylene sheets that overlap a minimum of two feet (2’) may be held in place using means other than an adhesive. The white polyethylene sheets shall be secured so that wind will not displace them. The Contractor shall immediately repair the broken or damaged portions or replace sections that have lost their waterproof qualities. If burlap and/or white polyethylene sheets are temporarily removed for any reason during the curing period, the Contractor shall keep the entire exposed area continuously wet. The saturated burlap and white polyethylene sheets shall be replaced, resuming the specified curing conditions, as soon as possible. The Contractor shall inspect the bridge deck surface once every eight (8) hours for the entirety of the curing period, so that all areas remain wet for the entire curing period and all curing requirements are satisfied and document the inspection in accordance with Subsection

804.03.17 1.1.

At the end of the curing period, one coating of liquid membrane shall be applied following the requirements of Subsection 804.03.17.1.2. The purpose of the coating of liquid membrane is to allow for slow drying of the concrete. The application of liquid membrane to any area shall be complete within 30 minutes of the beginning of removal of the white polyethylene sheets, soaker hoses, and burlap from this area.

804.03.17 1.1--Documentation for Bridge Decks. The Contractor shall provide the

Engineer with a daily inspection report that includes:

804.03.17 1.2--Liquid Membrane. At the end of the 14-day wet curing period the wet

burlap and polyethylene sheets shall be removed and within 30 minutes, the Contractor shall apply white liquid membrane to the deck. The liquid membrane shall be thoroughly mixed within the time recommended by the liquid membrane producer but no more than an hour before use. If the use of liquid membrane results in a streaked or blotched appearance, the method shall be stopped and water curing applied until the cause of defective appearance is corrected. The liquid membrane shall be applied when no free water remains on the surface but while the surface is still wet. The liquid membrane shall be applied according to the manufacturer’s instructions with a minimum spreading rate per coat of one (1) gallon per 200 square feet of concrete surface. If the concrete is dry or becomes dry, the Contractor shall thoroughly wet it with water applied as a fog spray by means of approved equipment. The application of liquid membrane shall be accomplished by the use of power applied spray equipment using nozzles and other equipment recommended by the liquid membrane producer. Manually pressurized or manual pump-up type sprayers shall not be used to apply the first application of liquid membrane. As a visual guide, the color of concrete covered with the required amount of liquid membrane should be indistinguishable from a sheet of commercially available standard “letter” size white copier paper placed on top of it when viewed from a distance of about five feet (5’) away horizontally if standing on the same grade as the concrete. The appearance of the concrete does not supersede applying the minimum spreading rate. The coating shall be protected against marring for at least seven (7) days after the application of the curing compound. The coating on bridge decks shall receive extra attention and may require additional protection as required by the Engineer. All membrane marred or otherwise disturbed shall be given an additional coating. Manually pressurized or manual pump-up type sprayers may be used for giving marred areas the required additional application of liquid membrane. Should the surface coating be subjected repeatedly to injury, the Engineer may require that the water curing method be applied at once. The 7-day period during which the liquid membrane is applied and protected shall not be reduced even if the period of wet curing is extended past the required 14 days.

804.03.17 1.2.1--Liquid Membrane Documentation. The Contractor shall make available

to the Engineer an application rate verification method and any information necessary during application of the liquid membrane to verify that the rate of application meets the prescribed rate for the various surfaces of the concrete, including, but not limited to, the top surface of the bridge deck and exposed sides of the bridge deck after any forms are removed. The Contractor shall submit this application verification method to the Engineer in accordance with Subsection 804.02.12.1.1. One method of verifying the rate of application is as follows:

804.03.17 2--Liquid Membrane Method. All surfaces on which curing is to be by liquid

membrane shall be given the required surface finish prior to the application of liquid membrane. Concrete surfaces cured by liquid membrane shall receive two applications of white liquid membrane. Neither application shall be made from a position supported by or in contact with the freshly placed concrete. Both applications shall be applied perpendicularly to the surface of the concrete. When using liquid membrane, the liquid membrane shall be thoroughly mixed within the time recommended by the liquid membrane producer but no more than an hour before use. If the use of liquid membrane results in a streaked or blotched appearance, the method shall be stopped and water curing applied until the cause of defective appearance is corrected. The application of liquid membrane shall be accomplished by the use of power applied spray equipment using nozzles and other equipment recommended by the liquid membrane producer. Manually pressurized or manual pump-up type sprayers shall not be used to apply the first two applications of liquid membrane. The liquid membrane shall be applied when no free water remains on the surface but while the surface is still wet. The liquid membrane shall be applied according to the manufacturer’s instructions with a minimum spreading rate per coat of one (1) gallon per 200 square feet of concrete surface. If the concrete is dry or becomes dry, the Contractor shall thoroughly wet it with water applied as a fog spray by means of approved equipment. The first application of the liquid membrane shall be made as the work progresses. For bridge decks, the first application shall be completed in each area of the deck, including the area in which the bridge railing will be later constructed, within 20 minutes of initial strike-off for bridges with no skew and within 25 minutes of initial strike-off for bridges with skew. For all other concrete, the first application of the liquid membrane shall be completed within 20 minutes of finishing. The second application shall be applied within 30 minutes after the first application. The liquid membrane shall be uniformly applied to all exposed concrete surfaces. As a visual guide, the color of concrete covered with the required amount of liquid membrane should be indistinguishable from a sheet of commercially available standard “letter” size white copier paper placed on top of it when viewed from a distance of about five feet (5’) away horizontally if standing on the same grade as the concrete. The appearance of the concrete does not supersede applying the minimum spreading rate. The Contractor shall make available to the Engineer an application rate verification in accordance with Subsection 804.03.17.1.2.1. The coating shall be protected against marring for at least 10 days after the application of the curing compound. The coating on bridge decks shall receive extra attention and may require additional protection as required by the Engineer. All membrane marred or otherwise disturbed shall be given an additional coating. Manually pressurized or manual pump-up type sprayers may be used for giving marred areas the required additional application of liquid membrane. Should the surface coating be subjected repeatedly to injury, the Engineer may require that the water curing method be applied at once. After the specified time for curing, but prior to constructing the bridge railing, all liquid membrane shall be removed from both the exposed surfaces of the reinforcing steel and the concrete surfaces on which bridge rail will be constructed. This removal of liquid membrane may be accomplish by high pressure washing or other methods approved by the Engineer.

804.03.18 Expansion and Fixed Joints, Bearings, Anchor Bolts, Plates, Castings,

Pipes, Drains, Conduits, Etc. All joints shall be constructed according to details shown on the plans. The edges of the concrete at open or filled joints shall be chamfered or edged as indicated on the plans.

804.03.18 1--Open Joints. Open joints shall be placed in the locations shown on the plans

and shall be constructed by the insertion and subsequent removal of a wood strip, metal plate, or other approved material. The insertion and removal of the template shall be accomplished without chipping or breaking the corners of the concrete. Reinforcement shall not extend across an open joint unless so specified on the plans.

804.03.18 2--Filled Joints. Poured expansion joints and joints to be sealed with premolded

materials shall be constructed similar to open joints. When premolded types are specified, the filler shall be placed in correct position as the concrete on one side of the joint is placed. When the form is removed, the concrete on the other side shall be placed. Adequate water stops of metal, rubber, or plastic shall be carefully placed as shown on the plans.

804.03.18 3--Premolded and Preformed Joint Seals. When preformed elastomeric

compressive joint seals are specified, the previously formed and cured open joint shall be thoroughly cleaned of all foreign matter, the required adhesive uniformly applied, and the seal installed in accordance with the recommendations of the manufacturer of the seal. When premolded filler is used for the joints in the roadway slab, the tops shall be adequately sealed with poured joint filler in accordance with details on the plans. Premolded filler shall be permanently fastened to an adjacent concrete surface by appropriate use of copper wire, copper nails, or galvanized nails.

804.03.18 4--Steel Joints. The plates, angles, or other structural shapes shall be accurately

shaped at the shop to conform to the section of the concrete floor. Fabrication and painting shall conform to the specifications covering those items. When called for on the plans or in the special provisions, the material shall be galvanized in lieu of painting. Care shall be taken to ensure that the surface in the finished plane is true and free of warping. Positive methods shall be employed in placing the joints to keep them in correct position during the placing of the concrete. The opening at expansion joints shall be that designated on the plans at normal temperature, and care shall be taken to avoid impairment of the clearance in any manner.

804.03.18 5--Water Stops. Adequate water stops of metal, rubber, or plastic shall be

placed as shown on the plans. Where movement at the joint is provided for, the water stops shall be of a type permitting movement without injury. They shall be spliced, welded, or soldered to form continuous watertight joints.

804.03.18 6--Bearing Devices. Bearing plates, rockers, and other bearing devices shall be

constructed according to details shown on the plans. Unless otherwise specified or set in plastic concrete, they shall be set in grout to ensure uniform bearing. Structural steel and painting shall conform to the requirements of Sections 810 and 814. When specified, the material shall be galvanized in lieu of painting. The rockers or other expansion bearing devices shall be set, considering the temperature at the time of erection, so that the required position of the device is provided. At all points of bearing contact, concrete members shall be separated from underlying members by dimensioned bearing pads or by methods and/or materials specified on the plans. When not otherwise specifically provided, contact areas between concrete super-structures and substructures shall be separated by three layers of No. 15, Type I, roofing felt.

804.03.18 7--Friction Joints. Metal friction joints shall consist of plates as indicated on

the plans and shall be securely anchored in correct position. All sliding surfaces shall be thoroughly coated with an approved graphite grease. Movement shall not be impeded by the concrete in which the plates are embedded.

804.03.18 8--Placing Anchor Bolts, Plates, Castings, Grillage, Conduits, Etc. All

anchor bolts, plates, castings, grillage, conduits, etc. indicated on the plans to be placed in or on the concrete shall be placed, set, or embedded as indicated or as directed. These items of the construction shall be set in hydraulic cement mortar as referenced in Subsection 714.11.5, except that anchor bolts may, as permitted by the Engineer, be built into the masonry, set in drilled holes, or placed as the concrete is being constructed by inserting encasing pipe or oiled wooden forms of sufficient size to allow for adjustment of the bolts. After removal of the pipe or forms, the space around the bolts shall be filled with hydraulic cement mortar completely filling the holes. The bolt shall be set accurately and perpendicular to the plane of the seat. Anchor bolts to be set in the masonry prior to the erection of the superstructure shall be carefully set to proper location and elevation with a template or by other suitable means. When bed plates are set in mortar, no superstructure or other load shall be placed thereon until this mortar has been allowed to set for a period of at least 96 hours, subject to the restrictions for cold weather concreting in Subsection 804.03.16.1. The mortar shall be kept well moistened during this period. Weep hole drains shall be installed in abutments and retaining walls, and roadway drains or scuppers shall be installed in the roadway slabs in accordance with the details shown on the plans. Where backfill is to be made at weep holes or openings in the structure, sand or stone chimneys or French drains shall be constructed as specified and shall extend through the portion of the backfill to be drained. Except as otherwise provided, the sand, stone, or slag used in this construction shall meet the requirements of Subsection 704.04.

804.03.19 Finishing Concrete Surfaces.

804.03.19 1--Classes of Finishes. Surface finishes of exposed concrete surfaces shall be

classified as follows: Class 1 - Ordinary Surface Finish Class 2 - Rubbed or spray Finish Class 3 - Tooled Finish Class 4 - Sand-Blast Finish Class 5 - Wirebrush or Scrubbed Finish Class 6 - Floated Surface Finish

804.03.19 2--Class 1, Ordinary Surface Finish. Immediately following the removal of

forms, all fins and irregular projections shall be removed from all surfaces except from those that are not to be exposed or not to be waterproofed. On all surfaces, the cavities produced by form ties and all other holes, honeycomb spots, broken corners or edges, and other defects shall be thoroughly cleaned, and after having been kept saturated with water for at least three hours, shall be carefully pointed and trued with a mortar of cement and fine aggregate mixed in the proportions used in the class of the concrete being finished. Mortar used in pointing shall be not more than one hour old. The mortar patches shall be cured as specified under Subsection 804.03.17. All construction and expansion joints shall be left carefully tooled and free of mortar and concrete. The joint filler shall be left exposed for its full length with clean and true edges. The resulting surfaces shall be true and uniform. All surfaces that cannot be repaired to the satisfaction of the Engineer shall be given a Class 2 rubbed finish.

804.03.19 3--Class 2, Rubbed or Spray Finish.

804.03.19 3.1--Rubbed Finish. After removal of forms, the Class 1 finish shall be

completed and the rubbing of concrete shall be started as soon as its condition will permit. Immediately before starting this work, the concrete shall be kept thoroughly saturated with water for at least three hours. Surfaces shall be rubbed with a medium course Carborundum stone using a small amount of mortar on its face. The mortar shall be composed of cement and sand mixed in the proportions used in the concrete being finished. Rubbing shall be continued until all form marks, projections, and irregularities have been removed, all voids are filled, and a uniform surface has been obtained. The paste produced by this rubbing shall be left in place at this time. After all concrete above the surface being treated has been cast, the final finish shall be obtained by rubbing with a fine Carborundum stone and water. This rubbing shall continue until the entire surface is of a smooth texture and uniform color. After the final rubbing is completed and the surface has dried, it shall be rubbed with burlap to remove loose powder and objectionable marks.

804.03.19 3.2--Spray Finish. Prior to the spray finish, the concrete shall be given a Class

1 finish in accordance with Subsection 804.03.19.2, supplemented if necessary with a grout meeting the requirements of Subsection 714.11 with fine aggregate modified to require 100 percent passing the No. 16 Sieve. Grout shall be applied with burlap pads or float sponges. As soon as the grout has dried, the surface shall be brushed to remove all loose grout and the surface left smooth and free of air holes. Surfaces to be sprayed shall be free of efflorescence, flaking coatings, dirt, oil, and other foreign substances. Prior to application of the spray finish, the surfaces shall be free of moisture, as determined by sight and touch, and in a condition consistent with the manufacturer's published recommendations. The spray finish material shall meet the requirements of Subsection 714.12 and shall be listed on the Approved Sources of Materials. The spray finish shall be applied with heavy duty spray equipment capable of maintaining a constant pressure as necessary for proper application. The material shall be applied as recommended by the manufacturer except the rate of application shall not be less than one gallon per 50 square feet of surface area without prior written approval of the Engineer. The completed finish shall be tightly bonded to the structure and present a uniform appearance and texture equal to or better than a rubbed finish. If necessary, additional coats shall be sprayed to produce the desired surface texture and uniformity. Upon failure to adhere positively to the structure without chipping or cracking or to attain the desired surface appearance, the coatings shall be completely removed and the surface given a rubbed finish in accordance with Subsection 804.03.19.3.1, or other approved methods shall be used to obtain the desired surface finish to the satisfaction of the Engineer without additional cost to the State.

804.03.19 4--Classes 3, 4, and 5 Finishes. If required, specifications for these finishes

will be contained in the special provisions.

804.03.19 5--Class 6, Floated Surface Finish. After the concrete has been deposited in

place, it shall be consolidated and the surface shall be struck off by means of a strike board and floated with a wooden or cork float. An edging tool shall be used on edges and expansion joints. The surface shall not vary more than 1/8 inch under a 10-foot straightedge. The surface shall have a granular or matte texture that will not be slick when wet.

804.03.19 6--Required Finishes for Various Surfaces.

804.03.19 6.1--General. Unless otherwise specified, the top surface of sidewalks, the top

horizontal surfaces of footings, and the top slabs of box bridges, box culverts, or other structures shall be given a Class 6 finish. All formed concrete surfaces shall be given a Class 1 finish, except on surfaces that are completely enclosed, such as the inside surfaces of cells of box girders, the removal of fins and form marks and the rubbing of mortared surfaces to a uniform color will not be required. In reference to finishing, exposed surfaces are surfaces or faces that may be seen after all backfill has been placed. Exposed surfaces requiring a Class 2 finish shall be finished at least one foot below the ground line or the low water elevation, whichever is higher. The Class 2 finish shall be made upon a Class 1 finish. After the removal of forms, the Class 1 finish shall be completed and the rubbing of concrete shall be started as soon as the condition of the concrete will permit. Bridge floors shall be finished in accordance with Subsection 804.03.19.7.

804.03.19 6.2--Finishing Formed Concrete Surfaces of Box Bridges, Box Culverts,

Pipe Headwalls, and Minor Structures. The exposed surfaces of wing walls and parapets of box bridges and box culverts to be used as vehicular or pedestrian underpasses shall be given a Class 2 finish. Exposed surfaces of other box culverts or box bridges, pipe culvert headwalls, and other minor structures shall be given a Class 1 finish unless otherwise indicated on the plans. The exposed surfaces of retaining walls including copings and parapets shall receive a Class 2 finish.

804.03.19 6.3--Finishing Formed Concrete Surface of Bridges. All exposed formed

concrete bridge surfaces shall have a Class 1 or 2 finish as set forth in this subsection unless designated otherwise on the plans. Bridges with designated surfaces for Class 2 finish are classified as follows: Group A - Bridges over highways, roads and streets. Group B - Bridges over waterways and railroads. Group BB - Twin or adjacent bridges of Group B category. When a Group B or BB bridge also spans a highway, road or street, exposed concrete surfaces shall be finished in accordance with Group A requirements.

804.03.19 7--Finishing Bridge Decks.

804.03.19 7.1--General. Concrete bridge decks shall be struck off and finished by the

method(s) designated on the plans. In the event a method is not designated, the Contractor may use either the longitudinal or transverse method subject to the requirements contained in these specifications. Except when indicated otherwise on the plans, the finish of the bridge deck shall be a belt finish, a broom finish, or one of the following drag methods: pan, double pan, burlap, or pan and burlap. Manual finishing of the bridge deck shall be performed only in areas inaccessible by the finishing equipment mounted to the strike-off screed, but shall not hinder the requirements for curing in accordance with Subsection 804.03.17.1. The surface texture specified and surface requirements shall be in accordance with the applicable requirements of Subsections 501.03.17 and 501.03.18 modified only as the Engineer deems necessary for bridge deck construction operations. At no time shall water on the surface of the concrete from bleeding, fogging, curing, or other sources be worked into the concrete or used as an aid for finishing. Regardless of the method of finishing selected, requirements for curing per Subsection

804.03.17 shall be completed within the specified time limits. If the requirements in

Subsection 804.03.17 are not completed within the specific time limits, the Contractor shall cease operations, revise his operations up to and including acquiring new or additional equipment or additional personnel in order to satisfy the requirements in Subsection

804.03 17, and, on approval from the Engineer, resume operations.

804.03.19 7.2--Longitudinal Method. The longitudinal method may be used for repairs

to bridge decks or bridge widening projects. For bridge widening projects, curing in accordance with Subsection 804.03.17 shall be completed within 30 minutes of initial strike-off for bridges without skew and within 35 minutes of initial strike-off for bridges with skew. The longitudinal method requires that the strike-off screed be supported on accurately graded and supported bulkheads or templates placed across the full width at the end(s) of the pour. Before the concrete is placed, approved fixed templates or wooden bulkheads of not less than 1¼-inch lumber shall be placed perpendicular to the centerline of the roadway, or in the case of skew bridges at the angle of skew. At least one dry run shall be made the length of each pour with a "tell-tale" device attached to the screed to assure the specified clearance to the reinforcing steel. The upper surface of the template or bulkheads shall be accurately set to conform to the required grade and crown. Special attention shall be given to the gutter lines where the strike-off screed cannot reach. The gutters shall be finished by hand and tested with the straight edge. Floor drains shall be set lower than the finished gutter line and finished over. After initial set, the concrete shall be dished out and finished around the drains to form an outlet. After the concrete has been deposited and rough graded, it shall be struck off by means of a strike-off screed resting on the bulkheads or fixed templates. The strike-off screed shall be of a type satisfactory to the Engineer and shall have sufficient strength to retain its shape under all working conditions. The final surface shall comply with the applicable requirements of Subsections 501.03.17.6 and 501.03.18, and unless otherwise specified in the contract, the final finish under this method shall be the belt finish. In general, the overall strike-off screed should be trussed, with bracing heavy enough to support the weight of a man without deflecting, and should be adjustable for camber and correction of sag. The strike-off screed will ride on the bulkheads or fixed templates at the ends of the section being finished. Care shall be taken to see that the bulkhead or fixed template elevations are accurately set since the entire span surface will be controlled by them. The manipulation of the screed shall be such that neither end is raised from the bulkheads or templates during the process. The concrete shall be struck off by beginning at one curb and proceeding entirely across the span. A slight excess of concrete shall be kept in front of the cutting edge at all times. This operation shall be repeated at least three times. In each case, the strike-off screed shall be picked up and carried back to the point of beginning. No backward strokes will be allowed. The strike-off screed shall be moved along the bulkheads or fixed templates with a combined longitudinal and transverse motion. This operation may be manual or mechanical. Standing or walking in the fresh concrete ahead of the strike-off screed will not be permitted.

804.03.19 7.3--Transverse Method. The transverse method requires that the screeding

equipment be supported on accurately graded and supported rails placed beyond the gutter lines and parallel with the centerline of the bridge. The machine shall be constructed and operated in a manner that produces a bridge deck of uniform density with minimum manipulation of the fresh concrete in the shortest possible time. Manual transverse methods of screeding will not be permitted. The finishing machine shall be supported on vertically adjustable rails set a sufficient distance from the gutter line to allow free movement of the screed from gutter line to gutter line. Satisfactory means of load distribution with minimum rail deflection shall be provided. The screed rails for a deck pour shall be completely in place for the full length of the pour and shall be firmly secured prior to placing concrete. The screed rails shall be adjusted as necessary to compensate for settlement and deflection occurring during the screeding operations. Supports for the screed rail shall be located directly over slab overhang support brackets as referenced in Subsection 804.03.14.1. At least one dry run shall be made the length of each pour with a "tell-tale" device attached to the screed carriage to assure the specified clearance to the reinforcing steel. The screed shall be equipped with a metal cutting edge or other approved mechanical means for accurately fine grading the plastic concrete to the required grade and surface smoothness and shall be supported by a bridging structure sufficiently rigid and heavy to perform operations satisfactorily on concrete of minimum slump without vibration, distortion, and wrecking of forms. The screed shall be mechanically actuated to deliver the screeding action and for travel in a longitudinal direction at a uniform rate along the bridge deck. The screed shall complete sufficient passes to strike off all of the excess concrete with ample mortar along the entire leading edge to assure filling of low spots. Care shall be taken to remove all objectionable material from the gutters where final hand finishing will be required. The selection of the transverse method may require the Contractor to furnish bridge deck concrete that contains an approved water-reducing set-retarding admixture in the quantities approved by the Engineer at no additional cost to the State. See Subsection 713.02 for more information. Other finishing requirements shall be in accordance with the general requirements in Subsection 804.03.19.7.1 and as specified on the plans.

804.03.19 7.4--Acceptance Procedure for Bridge Deck Smoothness. After the bridge

decks and bridge end slabs are completed and preferably before the construction of the bridge railing, they shall be tested for ride quality using a Contractor furnished profilograph. Profile Index Values shall be determined in accordance with Department SOPs and these specifications. The profilograph shall meet the requirements of Subsection

804.03.19 7.5. Profiles will be obtained in the wheel paths of the main thru lanes and,

where conditions allow, in the wheel paths of any auxiliary lanes or tapers. Profile Index Values for bridge decks and bridge end slabs shall be obtained for all State roads with four lanes or more, on State roads three lanes or less where the current traffic count is 2000 ADT or higher, or as designated on the plans. Ride quality tests will begin at a point where the rearmost wheel of the profilograph is as close to the beginning of the bridge end slab as possible and shall proceed forward across the remainder of the bridge end slab, across the bridge deck and continue across the next bridge end slab to a point where the front- most wheel of the profilograph reaches the far-most edge of the bridge end slab. In addition to the Profile Index test, all bridge decks and bridge end slabs shall meet a 1/8 inch in 10- foot straightedge requirement in both the longitudinal and traverse directions. Bridges and bridge end slabs not requiring a ride quality test must meet a 1/8 inch in 10-foot straightedge requirement in both the longitudinal and transverse directions. Bridges in horizontal curves having a radius of less than 1000 feet at the centerline and bridges within the superelevation transition of such curves are excluded from a test with the profilograph. The Profile Index Value for bridge decks including the bridge end slabs shall be averaged for the left and right wheel path for each lane and where applicable, each auxiliary lane and taper, and shall not exceed 65 inches per mile for each lane. Auxiliary lanes, tapers, shoulders and other areas that are not checked with the profilograph, shall meet a 1/8 inch in 10-foot straightedge check made transversely and longitudinally across the deck or slab. In addition, individual bumps or depressions exceeding 0.3 of an inch, when measured from a chord length of 25 feet, shall be corrected and the surface shall meet a 1/8 inch in 10-foot straightedge check made transversely across the deck or slab. Bridge decks and bridge end slabs not meeting the preceding requirements shall be corrected. Corrective work shall be done at no additional cost to the Department. Corrective work shall consist of grinding the bridge deck in accordance with this specification. All corrective work shall precede final surface texturing. After completion of final surface texturing, all surface areas corrected by grinding shall be sealed with a nonstaining 40% minimum alkylalkoxysilane penetrating sealant applied per the manufacturer’s directions. In case the bridge end slabs are to be constructed on a future project, the bridge deck(s) alone shall be tested for ride quality using the acceptance procedure outlined above, except that the ride quality test will begin at a point where the rearmost wheel of the profilograph is as close to the beginning of the bridge as possible and shall proceed forward across the bridge deck to a point where the front-most wheel of the profilograph reaches the far-most edge of the bridge. Expansion joint installation shall be delayed and the joint temporarily bridged to facilitate operation of the profilograph and grinding equipment across the joint wherever feasible. It shall be the Contractor’s responsibility to schedule profilograph testing. The Contractor shall notify the Department at least five (5) days in advance of profilograph testing. The Contractor shall ensure that the area to be tested has been cleaned and cleared of all obstructions. Profilograph testing of bridge decks and bridge end slabs shall be performed by the Contractor under supervision of the Engineer. All profilograph testing shall be performed at no additional cost to the Department. The Contractor will be responsible for traffic control associated with this testing operation.

804.03.19 7.4.1--Grinding Bridge Decks.

804.03.19 7.4.1.1--Equipment. The grinding equipment shall be a power driven, self-

propelled machine that is specifically designed to smooth and texture hydraulic cement concrete pavement with diamond blades. The effective wheel base of the machine shall not be less than 12.0 feet. It shall have a set of pivoting tandem bogey wheels at the front of the machine and the rear wheels shall be arranged to travel in the track of the fresh cut pavement. The center of the grinding head shall be no further than 3.0 feet forward from the center of the back wheels. The equipment shall be of a size that will cut or plane at least 3.0 feet wide. It shall also be of a shape and dimension that does not encroach on traffic movement outside of the work area. The equipment shall be capable of grinding the surface without causing spalls at cracks, joints, or other locations.

804.03.19 7.4.1.2--Grinding. The grinding areas will be determined by the Contractor and

approved by the Engineer. The Contractor shall develop and submit to the Engineer for approval a Grinding Plan. The Contractor shall allow up to 45 days for the Department to review the Plan prior to starting any grinding operations. This plan shall include as a minimum:

804.03.19 7.4.1.3--Final Surface Texture. The grinding process shall produce a finish

surface that is as close as possible to grade and uniform in appearance with a longitudinal line type texture. The line type texture shall contain parallel longitudinal corrugations that present a narrow ridge corduroy type appearance. The peaks of the ridges shall be approximately 1/16 inch higher than the bottoms of the grooves with approximately 53 to 57 evenly spaced grooves per foot. Grinding chip thickness shall be a minimum of 0.080 inches thick. The finished bridge decks and bridge end slabs shall be retested for riding quality using a Contractor furnished profilograph meeting the requirements of Subsection 804.03.19.7.5. The finished results shall meet the following conditions:

804.03.19 7.5--Profilograph Requirements. The smoothness of the bridge deck will be

determined by using a California Profilograph to produce a profilogram (profile trace) at each designated location. The surface shall be tested and corrected to a smoothness index as described herein with the exception of those locations or specific projects that are excluded from a smoothness test with the profilograph. The profilograph, furnished and operated by the Contractor under supervision of the Engineer, shall consist of a frame at least 25 feet in length supported upon multiple wheels having no common axle. The wheels shall be arranged in a staggered pattern so that no two wheels will simultaneously cross the same bump. A profile is to be recorded from the vertical movement of a sensing mechanism. This profile is in reference to the mean elevation of the contact points established by the support wheels. The sensing mechanism, located at the mid-frame, may consist of a single bicycle-type wheel or a dual-wheel assembly consisting of either a bicycle-type (pneumatic tire) or solid rubber tire vertical sensing wheel and a separate bicycle-type (pneumatic tire) longitudinal sensing wheel. The wheel(s) shall be of such circumference(s) to produce a profilogram recorded on a scale of one (1) inch equal to 25 feet longitudinally and one (1) inch equal to one (1) inch (full scale) vertically. Motive power may be provided manually or by the use of a propulsion unit attached to the center assembly. In operation, the profilograph shall be moved longitudinally along the pavement at a speed no greater than 3 MPH so as to reduce bounce as much as possible. The testing equipment and procedure shall comply with the requirements of Department SOP. The Contractor may elect to use a computerized version of the profilograph in lieu of the standard profilograph. If the computerized version of the profilograph is used, it shall meet the requirements of Subsection 804.03.19.7.5.1.

804.03.19 7.5.1--Computerized Profilograph.

804.03.19 7.5.1.1--General. The computerized profilograph, furnished and operated by

the Contractor under the supervision of the Engineer, shall be equipped with an on-board computer capable of meeting the following conditions of this subsection. Vertical displacement shall be sampled every three (3) inches or less along the bridge deck. The profile data shall be bandpass filtered in the computer to remove all spatial wavelengths shorter than two (2) feet. This shall be accomplished by a third order, low pass Butterworth filter. The resulting band limited profile will then be computer analyzed according to the California Profilograph reduction process to produce the required inches per mile index. This shall be accomplished by fitting a linear regression line to the length of bridge. This corresponds to the perfect placement of the blanking band bar by a human trace reducer. Scallops above and below the blanking band are then detected and totaled according to the California protocol. Bump/Dip analysis shall take place according to the California Profilograph reduction process. The computerized profilograph shall be capable of producing a plot of the profile and a printout that gives the following data: Stations every twenty five (25) feet, bump/dip height and bump/dip length of specification (3/10 of an inch and 25 feet respectively), the blanking band width, date of measurement, total profile index in inches per mile for the measurement, total length of the measurement, and the raw inches for each segment.

804.03.19 7.5.1.2--Mechanical Requirements. The profilograph shall consist of a frame

twenty five (25) feet long supported at each end by multiple wheels. The frame shall be constructed to be easily dismantled for transporting. The profilograph shall be constructed from aluminum, stainless steel and chromed parts. The end support wheels shall be arranged in a staggered pattern such that no two wheels cross a transverse joint at the same time. The relative smoothness shall be measured by the vertical movement of an eight (8) inch or larger diameter sensing wheel at the midpoint of the 25-foot frame. The horizontal distance shall be measured by a twenty (20) inch or larger diameter pneumatic wheel. This profile shall be the mean elevation referenced to the twelve points of contact with the pavement established by the support wheels. Recorded graphical trace of the profile shall be on a scale of one inch equals one inch (full scale) vertical motion of the sensing wheel and one inch equals 25 feet horizontal motion of the profilograph.

804.03.19 7.5.1.3--Computer Requirements. The computer shall have the ability to

produce output on sight for verification. The computerized output shall indicate the profile index for each specified section of bridge deck. Variable low and high pass third-order Butterworth filtering options shall be available. The printout shall be capable of showing station marks automatically on the output. Blanking band positioning for each specified section of the bridge deck shall be placed according to the least squares fit line of the collected data. Variable bump and dip tests shall be available to show “must correct” locations on the printout. The computer must have the ability to display on screen “must correct” conditions and alert the user with an audible warning when a “must correct” location has been located. The computer must have the ability to store profile data for later reanalysis. The measurement program must be menu driven and PC compatible. User selected options, identification, calibration factors, and time and date stamps shall be printed at the top of each printed report for verification. The control software must be upgradeable. A power source shall be included for each profilograph and be capable of supplying all power needs for a full days testing.

804.03.19 8--Finishing Horizontal Surfaces of Footings or Top Slabs of Box Bridges,

Culverts, or Other Structures. The finishing of horizontal surfaces of footing or top slabs of box bridges, culverts, or other structures shall be achieved by placing an excess of material in the form and removing or striking off the excess with a template, forcing the coarse aggregate below the mortar surface. After the concrete has been struck off the surface shall be given a Class 6 finish.

804.03.19 9--Finishing Exposed Surfaces of Sidewalks. After the concrete has been

deposited in place it shall be consolidated and the exposed surface shall be given a Class 6 finish. An edging tool of the required radius shall be used on all edges and at all expansion joints. The surface shall have a granular texture that will not be slick when wet. Sidewalk surfaces shall be laid out in blocks with an approved grooving tool as shown on the plans or as directed.

804.03.20 Opening Bridges.

804.03.20 1--Public Traffic. Unless otherwise specified, concrete bridge decks shall be

closed to public highway traffic for a period of at least 21 days after placing concrete.

804.03.20 2--Construction Traffic. Unless otherwise specified, concrete bridge decks

shall be closed to construction traffic for the time required for curing in Subsection

804.03.17 and the minimum required compressive strength for the concrete placed is

obtained.

804.03.21 Final Cleanup. Upon completion of the work all equipment, surplus materials,

forms, and waste material shall be removed, the bridge cleaned, and the site of the work given a final cleanup.

804.03.22 Precast-Prestressed Concrete Bridge Members.

804.03.22 1--General. All installations and plants for the manufacture of precast-

prestressed bridge members shall be PCI (Precast / Prestressed Concrete Institute) Certified. Bridge members manufactured in plants or installations not so approved will not be accepted for use in the work. The Contractor or other manufacturer shall employ a technician skilled in the adopted system of prestressing to supervise the manufacturing operations. This technician shall be certified according to the guidelines of this specification. The Contractor shall develop and implement a Quality Control Program as per Division I of PCI Quality Control Manual, Latest Edition. The Quality Control Program shall be submitted to the District Materials Engineer for approval.

804.03.22 2--Stressing Requirements. The jacks for stressing shall be equipped with

accurate calibrated gauges for registering the jacking pressure. Means shall be provided for measuring elongation of strands to at least the nearest 1/16 inch. Prior to beginning work, the Contractor or manufacturer shall have all jacks to be used, together with their gauges, calibrated by an approved laboratory. All jacks and gauges shall have an accuracy of reading within two percent. The testing agency shall furnish the Engineer a statement certifying that the jacks and gauges meet this requirement. During the progress of the work, if a gauge appears to be giving erratic results or if the gauge pressure and elongations indicate materially differing stresses, recalibration will be required. Calibration of jacks and gauges shall be repeated at intervals deemed necessary by the Engineer. These intervals for calibration shall not exceed one year. Shop drawings of prestressed beams, including an erection plan, shall be submitted in duplicate to the Bridge Engineer for approval prior to manufacture of members.

804.03.22 2.1--Methods. Plans for the particular bridge members will show prestressing

by one of the following methods:

Division V — of PCI Quality Control Manual, Latest Edition.

Division III — of PCI Quality Control Manual, Latest Edition.