511CONCRETE FOR STRUCTURES

511.01 Description

511.02 Materials

511.03 Concrete

511.04 Quality Control Requirements and Mass Concrete

511.0 5 Mixing of Concrete 511.0 6 Slump

511.07 Placing Concrete

511.08 Slipform Construction of Bridge Railing

511.09 Construction Joints

511.1 0 Work Stoppage 511.1 1 Depositing Concrete Under Water 511.1 2 Depositing and Curing Concrete During Cold Weather 511.1 3 Removal of Forms 511.1 4 Curing and Loading 511.1 5 Surface Finish 511.1 6 Roadway Finish

511.17 Bridge Deck Groo ving

511.18 Sidewalk Finish

511.19 Joints , Cracks , Scaling and Spalls

511.2 0 Compressive Strength

511.21 Air Content

511.22 Pay Factors

511.2 3 Method of Measurement 511.2 4 Basis of Payment

511.01 Description. This work consists of providing fa lsework and forming,

furnishing, placing, consolidating, finishing, and curing portland cement concrete. This work also includes diamond saw cutting longitudinal grooves into the surface of superstructure concrete. Construct falsework and forms as required in Item 508.

511.02 Materials. Furnish materials conforming to 499.02, except as modified

below. Use the same kind and color of aggregate for all concrete above the ground line in a given substructure unit and for all concrete in a given superstructure. Use high molecular weight methacrylate resin sealer conforming to 705.15. Use curing materials conforming to 705.05; 705.06 (white opaque); or 705.07;Type 1 or 1D. Use 1/4 -inch (6 mm) gray sponge joint filler conforming to 711.28, or use preformed filler c onforming to 705.03. Use preformed elastomeric compression joint seals conforming to 705.11. 511.03 343 511.03 Concrete . Provide concrete for structures according to 499.03, using Class QC 1, QC 2, QC 3 or QC 4 as specified in the Contract. At least 10 days before placing concrete , submit, in writing, the Department accepted Job Mix Formula (JMF) to the Engineer. The Engineer will review the mix design for conformance to contract requirements; otherwise the mix design is for the Engineer’s information.

511.04 Quality Control Requirements and Mass Concrete . When the concrete

bid item requires QC/QA, develop and submit a Quality Control plan (QCP) for the work and perform quality control testing of the concrete conforming to Item 455. When the concrete bi d item requires QC/QA, The Engineer will perform Quality Assurance conforming to 455. When the concrete bid item does not require QC/QA, the Engineer will make acceptance test cylinders as follows: Structures of 20 -foot (6.1 m) span or less. At least one set of test cylinders for each 50 cubic yards (35 m³) of concrete. Structures over 20 -foot (6.1 m) span. A set of test cylinders from each 200 cubic yards (150 m³) of concrete, or fraction thereof that is incorporated into the work each day. With any 511 concrete bid item provide and maintain a Concrete Cylinder Curing Box (CCCB) capable of holding at least twelve 4 × 8 inch (1 00 × 200 mm) cylinders at a temperature of 60 to 80 F (15 to 27 C) degrees no matter what the ambient temperature . The box will have a sealed lid. If the project has numerous 511 concrete bid items CCCB are not required for each bid item. Locate the CCCB at a site that is convenient to the concrete work and will eliminate handling damage to both the Contractor QC or QA cylinde rs and the Department Cylinders. Move the CCCB as needed during the project when the distance from the concrete work increases the possibility of cylinder handling damage.

499.03 Develop a TCP to control placement of the mass concrete so that the

highest maximum internal temperature of the placed concrete is not greater than 160 F (71 C). Submit the TCP to the Enginee r for acceptance at least 10 calendar days prior to placement along with the approved JMF (s). As a minimum, the TCP shall include the following information: 511.05 344 1. Duration and method of curing.

511.08 Slipform Construction of Bridge Railing. If slipforming, provide

finished concrete conforming to the following tolerances from plan dimensions: 511.08 349 TABLE 511. 08-1 SLIPFORMED BRIDGE RA ILING TOLERANCES Reinforcing steel cover -1/2 inch, +1/2 inch ( -13 mm, +13 mm) Top width dimension -0, +1/4 inch (+6 mm) Bottom width dimension -0, +1/2 inch (+13 mm) Surface flatness 1/4 inch in 10 feet (6 mm in 3 m) Vertical alignment (Deviation from a line parallel to the grade line) 1/2 inch in 20 feet (13 mm in 6 m) Max. ±1 inch (25 mm) Tie all joints and splices in bridge railing reinforcing steel. Before placing concrete, perform a slipforming dry run to ver ify reinforcing clearance and rigidity of the reinforcing cages. Adjust and stabilize the cage as necessary to establish the required clearances and to ensure the cage will not move during slipforming. The Contractor may add any additional diagonal reinfor cing steel between the front and rear vertical reinforcing faces to establish the required rigidity. Repair or patch honeycombing, cracking, tearing, and other defects immediately after concrete exits the slipform equipment. Completely fill defects with co ncrete without using water to smooth or close the surface . If the slipforming exhibits more than infrequent defects, stop work and make adjustments to produce a slipformed surface that does not require repairs. Do not broom finish the surface of the bridge railings. After the concrete initially sets, but before any shrinkage cracks develop, saw control joints 1 1/4 inches (32 mm) deep into the perimeter of the parapet. Generally, initial set is within 6 hours of batching of the concrete. Ensure that all control joints are sawed within 24 hours of placement. Saw control joints using an edge guide, fence, or jig to ensure that the joint is straight, true, and aligned on all faces of the parapet. The joint width shall be the width of the saw blade, a nominal 1 /4 inch (6 mm). After the concrete curing period specified in Item 511.14 has been reached, before applying construction loads on the deck (excluding personnel, hand operated equipment and manually powered vehicles) and before allowing vehicle traffi c in the lane immediately adjacent to median bridge railingsawcut each control joint at least 4 inches (100 mm) deep around the perimeter of the front face, top and back face of the top portion of parapet, no lower than 12 and ½ inches (313 mm) above the top of the concrete deck slab. Caulk the control joints with a polyurethane or polymeric material conforming to ASTM C 920, Type S. Slip formed concrete requires different slumps than those listed in Item 499 or other plan specified concrete. Provide a slump such that the concrete exiting the slipform does not pull but is stiff enough to prevent waviness and sags in the finished surfaces. Cure slipform concrete according 511.1 4, Method A. Because slipformed concrete has a low water -cement ratio, timely a pplication of the water cure is critical in helping control shrinkage cracks. Furnish platforms as necessary to protect traffic passing under the bridge from falling debris during the slipforming operation, to allow access for completing the finishing oper ation, and to allow the Engineer access to the outside of the parapet. 511.09 350 The Engineer will inspect the slipformed surface for horizontal cracking no earlier than 21 days after completion of the slipforming operation. Repair all horizontal cracks by epoxy inj ection. If a concrete sealer was applied, repair damage to the sealer after completing the epoxy injection.

511.09 Construction Joints. If construction joints are shown on the plans, place

all concrete between consecutive joints in a continuous operation. Follow the requirements of 511.14 when placing concrete against a construction joint. Obtain the Director’s approval before placing any construction joint not shown on the plans or required by 511. 07. Before placing concrete, determine the location where t he day’s concrete placing ends. If practical, end placing the day’s concrete perpendicular to the lines of principal stress and in regions of small shear. Do not install horizontal joints in concrete girders and beams. Form construction joints using bulkhe ads with keyways. Locate keyways clear of exposed surfaces by approximately one -third the thickness of the joint. Construct transverse or longitudinal construction joints in deck slabs with keys located between the reinforcing mats and having a depth of ¾ inch (19 mm). Where practical, avoid horizontal joints in piers, abutments, and retaining walls, otherwise locate horizontal joints 2 feet (0.6 m) or more above the normal water level. For construction joints not shown on the plans and above ordinary low w ater, in abutments, and in retaining walls that retain earth fills, install a 36 -inch (1 m) strip of Type 2 membrane waterproofing according to Item 512 to the back of the joint. Avoid joints in cantilevered members. Dampen the surface of the concrete of t he horizontal construction joints immediately before placing adjoining concrete. Place and protect horizontal construction joints between bridge slabs and superimposed curbs, parapets, sidewalks, and median strips in the same manner as the remainder of the slab. Cure the construction joints according to 511. 14. Avoid disturbing the bond between protruding reinforcing steel and the deck concrete. If using the curb areas to place the deck, tie and brace the reinforcing steel to prevent its movement. Where walls or columns support slabs or beams, place concrete in wall or column to the bottom of the slab or beam and allow the concrete to settle for at least 2 hours before placing concrete in the slab or beam.

511.10 Work Stoppage. If the work is unexpectedly interrupted by breakdowns,

storms, or other causes, rearrange the freshly deposited concrete to provide a suitable construction joint. If this joint occurs at a section with shear stress, prevent a plane of weakness by providing an adequate mechanical bon d across the joint by forming a keyway, inserting reinforcing steel, or by some other means satisfactory to the Engineer. 511.11 351 511.11 Depositing Concrete Under Water. Except for cofferdam seals and drilled shafts, do not place concrete under water.

511.12 Depos iting and Curing Concrete During Cold Weather . If placing

concrete when the atmospheric temperature is 32 °F (0 °C) or less, or if weather forecasts predict these temperatures during the curing period, follow the procedures of this subsection. Heat the wat er or aggregate, or both, as necessary to produce concrete with a temperature when placed of at least 50 °F (10 °C) but not greater than 70 °F (21 °C). Place concrete against materials with a temperature of greater than 32 °F (0 °C). If necessary, heat the forms, reinforcing steel, and foundation materials before placing the concrete. Maintain the concrete surface temperature between 50 and 100 °F (10 and 38 °C) for a period of not less than 5 days, except as modified in 511.1 2.C. After the minimum cure per iod of 5 days, reduce the concrete surface temperature at a rate not to exceed 20 °F (11 °C) in 24 hours until the concrete surface temperature is within 20 °F (11 °C) of atmospheric temperature. Install sufficient high -low thermometers to readily determin e the concrete surface temperature. For deck slabs, install high -low thermometers to measure deck bottom surfaces, deck fascia surfaces, and deck top surfaces. Maintain the concrete curing temperature using a heated enclosure, insulated forms, or by floodi ng, except cure deck slabs less than 10 inches (250 mm) thick using more than just insulated forms. Remove falsework and open cold weather concrete to traffic according to 511.1 4.

511.14 Curing and Loading. Remove falsework and open structures to traffic

only after the concrete has reached the strength specified by Table 511.1 4-1A for concrete bid items requiring QC/QA. Use Table 511.14.1B for concrete items not requiring QC/QA . Do not shorten the minimum required Method A curing time regardless of strength test results. TABLE 511.14 -1A LOADING REQUIREMENTS FOR CONCRETE REQUIR ING QC/QA Span[1] Required Strength [2] Removing Falsework Any Span Compressive Strength ≥ 0.85% f’c or Flexural Strength (Center point) ≥ 650 psi (4.5 Mpa) All pier caps Traffic Any [1] Span is defined as the horizontal distance between faces of the supporting elements when measured parallel to the primary reinforcement. [2] Field cured samples. The maturity curve method may be used for determining the strength according to Supplement 1098 in lieu of field curing samples 511.14 353 TABLE 511.1 4-1B LOADING REQUIREMENTS FOR CONCRETE NOT REQUIRING QC/QA Span[1] Age of Concrete in Days No Beam Test Beam Test [2] Removing Falsework Over 10 feet (3 m) 14 5 10 feet (3 m) or less and all pier caps 7 3 Traffic Any 14 7 [1] Span is defined as the horizontal distance between faces of the supporting elements when measured parallel to the primary reinforcement. [2] Applicable only when the average modulus of rupture for two tests is not less than 650 psi (4.5 MPa). Take enough specimens to verify compliance with the strength requirements of Table 511.14 -1A. Obtain samples from the first and last sublots of continuously placed concrete for quantities of 500 yd3 or less, and one extra set of specimens for each additional 500 yd3 or fraction thereof. Obtain samples in equally spaced increments throughout the placement as directed by the Engineer. De lays in placements of more than 4 hours are not considered continuously placed and are to be treated as separate placements. If the air temperature surrounding the concrete is maintained between 32 and 50 °F (0 and 10 °C), and if the provisions of 511.12 d o not apply, maintain the concrete above 32 °F (0 °C) for 7 days or until a successful strength test conforming to Table

511.14 1A, except this time shall not be less than 5 days .

Do not apply external loads to or perform work on new concrete until workers and construction materials will not damage the concrete or interfere with its curing. Allow at least 36 hours and until the field cured compressive strength cylinders or maturity results reach 85% f’c ; or if using flexural beams, the average of two beam tests is greater than 650 psi (4.5 MPa) before loading new concrete. 511.14 354 Cure concrete as follows: TABLE 511.14 -2, CURING REQUIREMENTS Location Curing Method [1] Superstructure concrete Method A Concrete to which sealer is applied Method A Construction joints Method A Top surface of concrete deck superstructure concrete Method A followed by Method B Concrete with waterproofing Method A or Method B All other concrete Method A or Method B [1] Method A is water curing. Method B is membrane curing. If using Method B on areas to be waterproofed, remove the curing membrane. Concrete curing methods are as follows:

705.06 Place plastic coated burlap blankets wet and with the burlap side against the

previous layer of wet burlap. Sufficiently lap and secure adjoining plastic coated blankets or polyethylene sheets at the laps and edges to form a seal that maintains the concrete wet at laps and edges. Cover white polyethylene sheeting or plastic coated blankets containing holes or tears with an additional covering of plastic sheeting or blankets as directed by the Engineer. Cover the top surface of deck superstructure concrete with a single layer of clean wet burlap after it is bull floated if necessary and fini shed. Keep the burlap wet by a continuous flow of water through soaker hoses and cover the hoses with a 4 mils (100 m) white opaque polyethylene film for 7 days. After 7 days, allow the surface of the deck to dry. After curing the top surface of the deck superstructure concrete for 7 days, remove the burlap and standing water. Within 12 hours after removing the burlap, apply a curing membrane and cure the concrete according to Method B.

511.17 Bridge Deck Grooving. After water curing the concrete and either bef ore

applying curing compound or some period after applying curing compound and before opening the bridge to traffic, saw longitudinal grooves into the deck, unless specified otherwise in the plans . If sawing grooves after applying the curing compo und and the concrete deck is less than 30 days old, reapply the curing compound after removing standing water, within 12 hours after sawing grooves in the deck. Use diamond blades mounted on a multi -blade arbor on self -propelled machines that were built fo r grooving of concrete surfaces. The groove machines shall have depth control devices that detect variations in the pavement surface and adjust the cutting head height to maintain the specified depth of the groove. The grooving machines shall have devices to control alignment. Do not use flailing or impact type grooving equipment. More than one size grooving machine may be required in order to saw the grooves as specified. Maintain a minimum of ¾ inch (19 mm) to a maximum of 2 ¼ inches (56 mm) transverse di stance between adjacent passes of the grooving machine head. Provide an experienced technician to supervise the location, alignment, layout, dimension, and grooving of the surface. 511.18 357 Saw grooves parallel to the bridge centerline in a continuous pattern acros s the surface. Begin and end sawing 9 to 12 inches (220 to 300 mm) from any device in place in a bridge deck, such as scuppers or expansion joints. Stop sawing a minimum of 2 inches (50 mm) to a maximum of 24 inches (600 mm) from skewed expansion joints. Maintain a clearance of a minimum of 2 inches (50 mm) and a maximum of 4 inches (100 mm) from the grooves to longitudinal joints in the deck. Maintain a minimum clearance of 9 inches (220 mm) to a maximum of 30 inches (750 mm) clearance between the grooves and the curb or parapet toe. However, at no point shall un -grooved portions of deck extend beyond edge line and into the temporary or permanent travelled lanes. Saw grooves in a uniform pattern spaced at 3/4 inch minus 1/4 inch or plus 0 (19 mm minus 6 mm or plus 0). Saw grooves approximately 0.15 inches (4 mm) deep and 0.10 inches (3 mm) wide. For staged, or phase bridge deck work, saw the grooves parallel to the final, permanent bridge centerline. If the different stages or phases of the bridge deck work occur within one construction season, any stage opened to traffic shall receive an interim coarse broom finish during placement, then saw the longitudinal grooves after the final stage. The interim broom finish will not be allowed as a surface texture when opened to traffic over a winter season. Saw longitudinal grooves in the deck prior to opening to traffic for a winter season. For bridge decks that widen from one end to the other, saw the longitudinal grooves parallel to the centerline of the roadway. On the side of the bridge that widens, saw the longitudinal grooves to follow the edge line. Saw longitudinal grooves in the gore areas, avoiding the overlapping of grooves. At the beginning of each work shift, furnish a full complement of grooving blades with each saw that are capable of cutting grooves of the specified width, depth, and spacing. If during the work, a single grooving blade on a machine becomes incapable of cutting a groove, continue work for the remainder of the work shift. The Contractor is not required to cut the groove omitted because of the failed blade. Should two or more grooving blades on a machine become incapable of cutting grooves, cease operating the machine until it is repaired. Continuously remove all slurry and remaining residu e from the grooving operation and leave the deck surface in a clean condition. Prevent residue from grooving operations from flowing across shoulders or across lanes occupied by public traffic or from flowing into gutters or other drainage facilities. Remo ve solid residue before the residue is blown by passing traffic or by wind. Provide water as necessary to saw grooves according to this subsection.

511.18 Sidewalk Finish. After placing, strike off the concrete with a template

and finish the concrete with a float to produce a sandy texture.

511.19 Joints , Cracks , Scaling and Spalls . After completing all curing

operations and allowing the deck to thoroughly dry, seal the following areas with a high molecular weight methacrylate (HMWM) sealer. Flood the areas and squeegee off the excess material as specified in Item 512 before opening the deck to traffic:

511.20 Compressive Strength . Sample and test concrete strength according to

511.04.

511.21 Air Content . For concrete that requires QC/QA, test the air content of

the concrete according to Item 455. When QC/Q A concrete is not required, the Department will test the air content as directed by the Engineer.

511.22 Pay Factors. Apply pay factors as follows:

511.20 A . 511.24

362 The Department will initially pay the full bid price to the Contractor upon completing the work. The Dep artment will calculate the final adjusted payment for each item as follows: PF1 - The final adjusted pay per cubic yard ( cubic meter) or square yard ( square meter), for accepted quantities of concrete : PF1 = (Contract Bid Price) x PF C PF2 - The final adj usted pay per cubic yard ( cubic meter) or square yard ( square meter) for unacceptable quantit ies of concrete due to compressive strength or low air content and allowed to stay in place, according to 511.20 or 511.21 . PF2 = (Contract Bid Price) x 0.75 Calculate the adjusted price per bid item by multiplying PF1 or PF2 by the appropriate quantities of concrete, then sum the values. Subtract the full bid price paid to the Contractor from the adjusted price to determine the difference. The Department will exec ute final adjustments by change order upon receipt of all test data. The Department will pay for accepted quantities at the contract prices as follows: Item Unit Description 511 Cubic Yard Class ___ Concrete, _____ (Cubic Meter) 511 Cubic Yard Class ___ Concrete, _____ with QC/QA (Cubic Meter) 511 Cubic Yard Class QC 1 Concrete, Substructure (Cubic Meter) 511 Cubic Yard Class QC 1 Concrete, Substructure with (Cubic Meter) QC/QA 511 Cubic Yard Class QC 2 Concrete, Bridge Deck (Cubic Meter) Square Yard (Square Meter) 511 Cubic Yard Class QC 2 Concrete, Bridge Deck with (Cubic Meter) QC/QA Square Yard (Square Meter) 511 Cubic Yard Class QC 2 Concrete, Bridge Deck (Parapet) (Cubic Meter) 511 Cubic Yard Class QC 2 Concrete, Bridge Deck (Parapet) (Cubic Meter) with QC/QA 511 Cubic Yard Class QC 3 Concrete, _____ with QC/QA (Cubic Meter) 511 Cubic Yard Class QC 4 Mass Concrete, Substructure with (Cubic Meter) QC/QA 512.01 363 ITEM 512 TREATING CONCRETE

512.01 Description

512.02 Materials

512.03 Sealing of Concrete Surfaces

512.04 Sealing Concrete Bridge Decks with HMWM Resin

512.05 Soluble Reactive Silicate (SRS) Concrete Treatment

512.06 Treating Concrete Bridge Decks with Gravity -Fed Resin

512.07 Sealing Cracks by Epoxy Injection

512.08 Waterproofing

512.09 Method of Measurement

512.10 Basis of Payment

512.01 Description. This work consists of sealing and treating concrete

surfaces, sealing cracks in concrete, and applying waterproofing to structures.

512.02 Materials. Furnish materials conforming to:

Asphalt cement ................................ .. 702.01 (PG 64 - 22) Asphalt primer for .................. 702.02 (RC -70 or RC -250), waterproofing ................................ ..................... 702.05 HMWM Resin ................................ ........................ 705.15 Epoxy -Urethane Sealer ................................ ....... 705.23.A Non-epoxy Sealer ................................ ............... 705.23.B Soluble Reactive Silicate (S RS) .............................. 705.24 Gravity Fed Resin ................................ ................... 705.25 Epoxy injection Materials ................................ ....... 705.26 Sand ....................... 703 with the following exceptions: Maximum moisture content of 0.5 of the percent of absorption when treated according to California Test 226. Gradation: Sieve Size Total Percent Passing No. 4 (4.75 mm) 100 No. 8 (2.36 mm) 90 to 100 No. 20 (850 µm) 5 to 15 No. 50 (300 µm) 0 to 5 Emulsified asphalt primer, ................ 702.04 (MS -2, SS -1) Asphalt for waterproofing ................................ ....... 702.06 Hot applied joint sealer ................................ ........... 705.04 Type 3 membrane primer ................................ ........ 705.04 Waterproofing fabric ................................ ............... 711.24 Sheet Type 2 membrane waterproofing .................. 711.25 Sheet Type 3 membrane waterproofing .................. 711.29

512.03 Sealing of Concrete Surfaces . This work consists of applying an

approved sealer on existing and new concrete surface areas after the concrete is cured and repairs completed and cured. Apply the sealer to locations described in the plans. Apply the sealer listed in the pay item description. Choose a type of sealer if no sealer is listed in the pay item description. 512.03 364 A. Equipment. Use appl ication equipment recommended by the sealer manufacturer. Use spray equipment, tanks, hoses, brooms, rollers, coaters, squeegees, etc., that are clean, free of foreign matter, oil residue and water.

512.05 Soluble Reactive Silicate (SRS) Concrete Treatment . This item

consist of the necessary labor, materials and equipment to prepare and treat portland cement concrete surfaces with a reactive silicate sealer meeting these specifications.

107.19 .

512.06 Treating Concrete Bridge Decks with Gravity -Fed Resin. This work

shall consist of preparing and treating the concrete bridge deck with a gravity -fed crack welding system in accordance with these specifications in reasonably close conformity with the plans and the manufactur er’s recommendations and as directed by the Engineer.

512.07 Sealing Cracks by Epoxy Injection . This specification covers the repair

of dry, moist or wet cracks or fractures that are 2 to 100 mils (50 to 2500 µm) in thickness in reinforced concrete members. The repair is by means of an e poxy injection system. This system shall consist of a paste epoxy used to seal the surface cracks and an injection epoxy used under low pressure, 200 psi (1400 kPa) max., to penetrate and fill the cracks and bond the crack surfaces together. Material for e ach epoxy shall consist of a two -component modified resin bonding system. The unmodified resin shall be known as Component A and the hardener as Component B. Arrange to have a manufacturer ’s representative at the job site to familiarize him and the Enginee r with the epoxy materials, application procedures and recommended pressure practice. This representative shall direct at least one complete crack or area injection and be assured prior to his departure from the project that the personnel are adequately in formed to satisfactorily perform the remaining repairs. Furnish the Engineer a copy of the manufacturer ’s comprehensive preparation, mixing and application instructions which have been developed especially for use with the proposed epoxy injection system. Ensure that any significant changes to these instructions which are recommended by the representative for an unanticipated situation have been approved by the Engineer prior to the adoption of such changes. Clean concrete surfaces adjacent to the cracks to be sealed only to the extent necessary to achieve an adequate bond with the paste epoxy, and only by procedures which will not cause abrasive grits or concrete dust to penetrate the cracks. Do not permit the use of solvents or thinners in cracks or on bon ding surfaces. Install injection ports or tees in cracks to be injected. Space injection ports or tees at 6 to 12 inches (150 to 300 mm) vertically and 6 to 18 inches (150 to 450 mm) horizontally but in no case closer together than the thickness of the co ncrete member if full depth penetration is desired unless otherwise specified or directed. Set ports or tees in dust free holes made either with vacuum drills or chipping hammers. Seal all surface cracks in the area to be repaired, after injection ports or tees have been inserted into the holes, with paste epoxy between ports to ensure retention of the pressure injected epoxy within the confines of the member. The Department will allow an alternative procedure of sealing the cracks before the injection hole s have been made. Limit the application of paste epoxy to clean and dry surfaces. Limit substrate temperatures to not less than 45 °F(7 °C) during epoxy applications. 512.08 373 Begin the epoxy injection at the bottom of the fractured area and progress upward using a port or tee filling sequence that will ensure the filling of the lowermost injection ports or tees first. Establish injection procedures and the depths and spacings of holes at injection ports or tees. Use epoxy with flow characteristics and injection pr essure that ensure no further damage will be done to the member being repaired. Ensure that the epoxy will first fill the innermost portion of the cracked concrete and that the potential for creating voids within the crack or epoxy will be minimized. Remo ve the injection ports or tees flush with the concrete surface after the fractured area has been filled and the epoxy has partially cured (24 hours at ambient temperature not less than 60 °F (16 °C), otherwise not less than 48 hours). Roughen the surfaces of the repaired areas to achieve uniform surface texture. Remove any injection epoxy runs or spills from concrete surfaces. Obtain two 4 -inch (100 mm) diameter core samples in the first 100 linear feet (30 m) of crack repaired and one core for each 100 linear feet (30 m) thereafter. Take the core samples from locations determined by the Engineer and for the full crack depth. Cores will be visibly examined by the Engineer to determine the extent of epoxy pene tration. Repair the core holes in the concrete with material specified in 705.21.

512.08 Waterproofing

711.29 The application of this product shall follow the manufacturer’s written

recommendations, which shall be provided to the project. Keep membrane and primer materials dry before installation. Heat the membrane primer in an oil primer heated, double -jacket kettle. Use a kettle that is clean and free of other materials with any obvious buildup scraped out. The Contractor may use a single -jacket kettle if the primer is capable of being heated in direct fire to the applica tion temperature. Heat primers within the manufacturer’s recommended temperatures. On bridges with curbs, apply the primer and membrane 3 inches (75 mm) up the curb face. On prestressed box beam bridges with no approach slab, apply the primer and membrane 6 inches (150 mm) over the ends of the beams. On prestressed and slab bridges with approach slabs, apply the primer 2 feet (600 mm) out onto the approach slab. If the plans require a Type 3 membrane on the top exterior surface of precast concrete three - or four-sided structures, apply the primer and membrane to overlay the vertical exterior sides of the structure by 12 inches (300 mm). Apply primer no further than 5 feet (1.5 m) in front of the membrane using a squeegee to fill all voids and imperfections. Apply membrane from the low to the high side of the surface. Apply an extra bead of primer at the edge of the membrane. Lap joints in membranes by at least 3 inches (75 mm). After installing the membrane over the entire surface, seal joints in the membrane by applying primer and smoothing with a V -squeegee. If asphalt pavement is to be placed directly over the water proofing membrane, first apply tack coat as specified in 407 without damaging the membrane. 512.09 376 512.09 Method of Measurement. The Department will m easure Waterproofing, of the type specified, by the number of square yards (square meters) or on a lump sum basis. The Department will measure sealing of concrete surfaces by the number of square yards (square meters) of coated area projected to a two -dime nsional surface. The Department will measure the removal of existing coatings from concrete surfaces in square yards (square meters) removed. The Department will measure the sealing of concrete bridge decks with HMWM resin and treating concrete bridge deck s with SRS as the actual area in square yards (square meters ) of surfaces treated. The Department will measure the actual length in linear feet (meters) of crack repaired by epoxy injection.

512.10 Basis of Payment. The Department will pay for accepted quantities at

the contract prices as follows: The Department will consider the cost for the obtaining and repairing the two cores used by the Engineer to determine the extent of the epoxy penetration as incidental to the work of repairing the concrete by e poxy injection. The Department will consider the removal of dust, dirt, oil, wax, curing compounds, efflorescence, laitance, and other foreign materials as incidental to the surface preparation of the concrete surfaces to be sealed. When the surface to be sealed contains an existing coating, the Department will consider all materials, equipment and labor to remove the existing coating as incidental to the removal of existing coatings. Item Unit Description 512 Square Yard Sealing of concrete surfaces (Square Meter) 512 Square Yard Sealing of concrete surfaces (Square Meter) (non-epoxy) 512 Square Yard Sealing of concrete surfaces (Square Meter) (epoxy urethane) 512 Square yard Sealing of concrete bridge (Square Meter) decks with HMWM resin 512 Square yard Treating concrete bridge (Square Meter) decks with SRS 512 Square yard Treating concrete bridge (Square Meter) decks with Gravity -Fed Resin 512 Foot Concrete repair by epoxy injection (Meter) 512 Square Yard Type A Waterproofing (Square Meter) or Lump Sum 512 Square Yard Type B Waterproofing (Square Meter), or Lump Sum 513.01 377 512 Square Yard Type E Waterproofing (Square Meter), or Lump Sum 512 Square Yard Type 2 Waterproofing (Square Meter), or Lump Sum 512 Square Yard Type 3 Waterproofing (Square Meter), or Lump Sum 512 Square Yard Removal of Existing Coatings from Concrete (Square Meter) Surfaces ITEM 513 STRUCTURAL STEEL MEM BERS

513.01 Description

513.02 Fabricator Approval Procedure

513.03 Levels of Fabricator Quali fication

513.04 General

513.05 Fabricator Documentation Responsibility

513.06 Shop Drawings

513.07 Levels 1 through 6, Pre fabrication Meeting

513.08 Materials

513.09 Material Control

513.10 Care of Material

513.11 Workmanship and Straightening

513.12 Finis h

513.13 Stiffeners

513.14 Fillers

513.15 Horizontally Curved Beams and Girders

513.16 Joints and Splices

513.17 Pin Holes

513.18 Pins and Rollers

513.19 Holes for High -Strength and Bearing Bolts

513.20 High -Strength Steel Bolts, Nuts, and Washers

513.21 Welding

513.22 Stud Shear Connectors

513.23 Threads for Bolts and Pins

513.24 Shop Assembly

513.25 Nondestructive Testing

513.26 Shipping, Storage, and Erection

513.27 Shop Coating

513.28 Cleaning ASTM A 709/A 709M, Grade 50W (345W) Steel

513.29 Method of Measurement

513.30 Basis of Payment

513.01 Description. This work consists of preparing shop drawings, furnishing

and fabricating structural steel members, nondestructive testing, fabricator performed quality control, documentation, cleaning, shop coatin g, and erecting 513.02 378 structural steel and other structural metals. Prepare shop drawings and erect structural steel according to Item 501 and the additional requirements below. Shop painting shall conform to Item 514. The work also includes any work to move existing steel structures to the plan location, making necessary repairs and alterations, and connecting or joining new and old construction. The terms “main,” “secondary,” or “detail,” as referred to in Item 513, are defined as follows: “main” refers to mate rial, members, and fasteners that are primarily stressed by live load and structure weight; “secondary” refers to material, members, and fasteners that do not directly support live load or main members; “detail” refers to essential non -structural material, members, and fasteners.

513.02 Fabricator Approval Procedure. Select fabricators that are listed by

the Department before the Contract letting date as evaluated by the Office of Materials Management and prequalified according to Supplement 1078. The Offic e of Materials Management may accept subletting of processes that require specialized machinery or knowledge. Submit written requests for subletting to the Office of Materials Management. The Office of Materials Management will determine if the process is uncommon and will evaluate the qualifications of the proposed sublet fabricator. The fabricator’s quality control staff shall witness and perform quality control of the sublet work.

513.03 Levels of Fabricator Qualification. There are eight levels of fabri cator

qualification. The Office of Materials Management will classify each fabricator at the highest level of fabrication it is qualified to perform. 513.04 379 Level Description of Capabilities SF Standard fabricated members described and paid for as Item 516, 517, and 518 and detailed by standard bridge drawings. Material and fabrication acceptance by certification with random Department audits of the work and documentation. UF Unique fabricated members not covered by standard bridge drawings and not designed to c arry tension live load. Examples include curb plates, bearings, expansion joints, railings, catwalk, inspection access, special drainage, or other products. Examples also include retrofit cross frames, retrofit gusset plates, retrofit lateral bracing, or o ther miscellaneous structural members not included in Levels 1 through 6. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078. 1 Single span, straight, rolled beam bridges without stiffeners, Secondary an d Detail materials designed to carry tension live loads such as retrofit moment plates. Case II Loading. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078. 2 Multiple span, straight, rolled beam bridges without stiffeners. Case II loading. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078. 3 Single or multiple span, straight, dog legged, or curved, rolled beam bridges including stiffeners. Case I or II Loading. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078. 4 Straight or bent welded plate girder bridges. Case I or II loading. Quality assurance of shop drawings, material test reports, and inspec tion according to Supplement 1078. 5 Straight, curved, haunched, or tapered welded plate girder bridges. Case I or II loading. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078. 6 Truss bridges, fractu re critical bridges, fracture critical members, or fracture critical components new or retrofitted. Case I or II loading. Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

513.04 General.

Perform all steel fabrication including the shop application of coatings in a pre - qualified structural steel fabricating shop consisting of adequately sized permanent buildings with equipment, heat and light, and experienced personnel to satisfactorily perform all ne cessary operations. Perform flame cutting, air carbon -arc gouging, cambering, welding, cleaning, and painting inside permanent buildings that are maintained at the required environmental conditions. The fabricator may perform shop assembly of large pieces for fit -up of field connections outdoors. These provisions will not apply to steel requiring fabrication at the bridge site in the repair, alteration or extension of an existing structure. If repairing, extending, or altering existing structures, take measurements of the existing structure as required to accurately join old and new work. Include these measurements on shop drawings. Measurements shown on the plans that indicate the extent and nature of repair, alterations or extension shall not relieve t he Contractor of this responsibility. 513.05 380 At least two weeks before starting shop fabrication, the fabricator shall notify the Office of Materials Management and furnish a proposed fabrication schedule for the work. Unless the Office of Materials Management pr ovides a written waiver of a hold or witness point inspection, the fabricator shall store members completed during the inspector’s absence in a manner that allows the inspector to completely and safely inspect the finished work. The fabricator shall not sh ip fabricated members performed under Item 513, UF Level or Levels 1 through 6 from the shop without prior hold point inspections unless the Office of Materials Management waives the inspection. The Office of Materials Management will not conduct the sched uled final inspection until the fabricator completes and inspects with documentation, final fabrication and shop coatings and the Contractor documents approval of shop drawings and material test reports. The Office of Materials Management will not conduct a final fabrication inspection of SF Level members. Instead, the Office of Materials Management will conduct random inspections during the fabricator’s work. The fabricator shall provide an office with the following attributes:

513.05 Fabricator Documentation Responsibility. The fabricator shall keep

and maintain documentation records as specified in Supplement 1078. At the Department’s request, provide access to the above documents for audit, inspection, and copying.

513.06 Shop Drawing. Provide shop drawings conforming to 501.04 and the

following requirements: Include details, dimensions, size of materials, match mark diagrams for field connections, a diagram identifying, by some unique mark, each area of a welded splice to be covered by a single radiograph, and other information necessary for the complete fabrication and erection of the metal work. For multiple span beam and girder bridges, include an overall layout with dimensions showing the relative unloaded vertical and horizontal position of beam or girder segments with respect to a full length base or work line. Account for 513.07 381 camber and horizontal curvature of the beams or girders, and the effect of deck surface profile in this layout. Show required offsets for vertical and horizontal curvature at approximately each one -fourth of span length, at field splices, and at bearing points. For horizontally curved members, show the offset to a baseline strung from end to end of the member, every 10 feet (3 m) of length. Identify the grade (ASTM designation), CVN, fracture critical, or any special testing requirements for each piece of steel. Identify pieces made of different grades of steel with different assembling or erecting marks, even if the pieces have identical dimensions and detail. Identify the welding procedure by the WPS number at each joint and the location and identification numbers of all radiograph tests. Detail structural steel to fit under full steel dead load and prior to deck placement with the webs of p rimary members plumb.

513.07 Levels 1 through 6, Pre fabrication Meeting. After providing the notice

and schedule required by 513.04 and at least 3 days after the Department receives shop drawings, conduct a prefabrication meeting at the fabricator’s facili ties, or another location agreed to by all parties. The fabricator and its quality control specialists for fabrication and painting, the inspector, and the Contractor, or its designated representative, shall attend the meeting. The purpose of this meeting is to review any fabrication issues, including information on shop drawings, inspection, hold or witness points, unique fabrication items, special processes, and both the fabrication and project schedule. The fabrication quality control specialist shall co nduct the meeting and record and distribute meeting minutes that document all issues discussed. Fabrication may begin after the prefabrication meeting is complete.

513.08 Materials. Furnish materials conforming to 501.06.

513.09 Material Control. Identify and mark each piece of steel according to the

shop drawings and the following requirements. Immediately after removing steel that is furnished in tagged lifts or bundles, mark the individual pieces of steel with the ASTM A 6/A 6M specification identificati on color code and heat number. The fabricator may furnish material from stock that is marked with the heat number and mill test report. If separated from the full -size piece furnished by the supplier, mark excess material placed in stock for later use with the heat number and, if provided, with the ASTM A 6/A 6M specification identification color code. During fabrication, clearly and legibly mark the specification identification color code and heat number on each piece of steel. Before cutting steel into smaller size pieces, clearly and legibly mark each smaller size piece with the ASTM A 6/A 6M specification identification color code and heat number. Unless otherwise approved by the inspector, mark pieces of steel that will be subject to fabricating opera tions such as blast cleaning, galvanizing, heating for 513.10 382 forming, or other operations that may obliterate paint color code and heat number markings with steel stamps or with a substantial tag firmly attached to the piece of steel. At locations acceptable to the Office of Materials Management, stamp the heat numbers into main material tested for CVN. Issue cutting instructions by cross -referencing the assembly marks shown on the shop drawings with the corresponding item covered on the mill purchase order. The fabricator’s system of assembly -marking individual pieces of steel and issuing cutting instructions shall provide a direct reference to the appropriate mill test report. The fabrication quality control specialist shall provide the Engineer with a letter documenting that the fabricator performed material control according to this specification.

513.10 Care of Material. Store structural material at the shop or field above the

ground, upon platforms, skids, or other supports. Use straight structural steel with clean and dry surfaces before working it in the shop. Before using, clean all rusted or corroded material. Only use this material if it conforms to ASTM A 6/A 6M thickness tolerances after cleaning.

513.11 Workmanship and Straightening. If necessary to st raighten rolled

material, use methods that will not damage the member. If carefully planned and supervised, apply localized heat for straightening. Do not allow the temperature of the heated area to exceed 1150 F (620 C) as controlled by pyrometric stick or thermometers. Do not quench to accelerate cooling. Do not kink or offset the material if using mechanic or hydraulic force to camber or strengthen material. Do not cold bend fracture critical materials. Camber rolled beams as shown on the plans in the prequalified fabricating shop using heat or hydraulic jacks. Control heating as specified above and follow a formal shop heating procedure. Camber plate girders by trimming web plates before assembly. During fabrication, shipping, and erection, support and handle members to maintain camber. Fabricate structural steel to within the dimensional tolerances specified by Articles 3.5 of the AASHTO/AWS Bridge Welding Code , with the following modifications:

513.12 Finish. Plane she ared edges of all main material to a minimum depth of

1/4 inch (6 mm) except for ASTM A 709/A 709M, Grade 36 (250) steel having a thickness of 5/8 inch (16 mm) or less. Remove fins, tears, slivers, and burred or sharp edges from steel members by grinding. If these conditions appear during the blasting operation, re -grind and re -blast the steel members to the required surface profile. The fabricator may flame cut structural steel. Provide a smooth surface, free from cracks and notches, and use a mechanical g uide to provide an accurate profile. Roll and flame cut surfaces according to the AASHTO/AWS Bridge Welding Code , as amended by Supplement 1011. Provide a surface finish for bearing and base plates and other bearing surfaces that contact each other or conc rete according to ANSI B46.1, Surface Roughness, Waviness and Lay, Part I. TABLE 513.12 -1, ANSI B46.1 Steel slabs 2000 mil (50.0 µm) Heavy plates in contact in shoes to be welded 1000 mil (25.0 µm) Milled ends of compression members, milled or ground ends of stiffeners and fillers 500 mil (12.5 µm) Bridge rollers and rockers 250 mil (6.4 µm) Pins and pin holes 125 mil (3.2 µm) Sliding bearings 125 mil (3.2 µm)

513.13 Stiffeners. Place the bearing end of bearing stiffeners flush and square

with the web and in a manner so at least 75 percent of the area of the bearing end is in contact with the inner surface of the flange. The other end of the bearing stiffener shall have a tight fit as defined below. Position bearing stiffeners to be vertical after erection. Weld intermediate stiffeners that are not used in pairs to the compression flange, and provide a tight fit for the tension flange. Weld intermediate stiffeners connected to cross frame angles to the top and bottom flange. A tight fit is defined a s the contact between the stiffener and flange over some portion of the end of the stiffener and having no gap greater than 1/16 inch (1.6 mm). Clip stiffeners 2 1/2 inches (65 mm) along the web and 1 inch (25 mm) along the flange to clear flange -web welds and fillet or rolled shapes. When attaching stiffeners to the web and flanges, do not extend welds to the edge of the stiffeners or into the clip area. Terminate these welds 1/4 ±1/8 inch at the flange connections and 1/2 ±1/4 inch at the web connection.

513.14 Fillers. Detail the shop drawings to show fill plates that compensate for

the misalignment of abutting elements due to differences in thickness of flanges and webs at the splice locations. Detail the fill plates to the nearest 1/16 inch (1.6 mm) in thickness, but not less than 1/8 inch (3 mm) thick. However, in the final shop assembly, furnish fills of sufficient thickness to compensate for misalignment of abutting elements due to standard rolling mill tolerances or due to differences in 513.15 384 thicknesses of flanges and webs at the splice location. The actual fills used shall compensate for differences in total thickness or relative positions of more than 1/16 inch (1.6 mm) but with no fills less than 1/8 inch (3 mm) thick. Provide fill plates in bolted joi nts that are flush with the perimeter of the splice plates.

513.15 Horizontally Curved Beams and Girders. If members are to be heat

curved, submit the detailed procedure, including necessary calculations, to the Office of Materials Management. Obtain the O ffice of Materials Management’s acceptance of the procedure before starting this work. Curve beams and girders using heat according to AASHTO Standard Specifications for Highway Bridges , except that the fabricator may cut flanges for girders to obtain the required alignment.

513.16 Joints and Splices. In bolted construction where tension or flexural

members are spliced, maintain a clearance of not more than 1/4 inch (6 mm) between the abutting surfaces of spliced members. For spliced compression members, fa ce the abutting surfaces to provide a uniform bearing when properly aligned and completely bolted. In welded construction, prepare abutting surfaces as shown on the shop drawings. Verify the preparation for field welded butt joints in main members by a com plete shop assembly according to 513.24.

513.17 Pin Holes. Bore pin holes after the member is fabricated and true to size,

at right angles to the axis of the member and parallel to each other. Pin holes for up to 5-inch (127 mm) diameter pins shall not exc eed the pin diameter by more than 0.020 inch (0.51 mm) and pin holes for larger pins shall not exceed the pin diameter by more than 0.031 inch (0.79 mm).

513.18 Pins and Rollers. Use pins and rollers made from cold rolled steel,

accurately turned to size, straight and smooth, and entirely free from flaws. Pins over 9 inches (230 mm) in diameter shall be annealed. In pins larger than 9 inches (230 mm) in diameter, bore a hole not less than 2 inches (50 mm) in diameter the full length of the axis. Furnish one pilot and one driving nut for each size of pin.

513.19 Holes for High -Strength Bolts and Bearing Bolts . Provide cylindrical

holes, perpendicular to the member, clean cut, and free of ragged edges. Remove burrs by countersinking not more than 1/16 inch (1.6 mm) or by grinding. Provide finished holes with a diameter not larger than the nominal diameter of the bolt plus 1/16 inch (1.6 mm). The hole diameter shall not vary by more than 1/32 inch (0.8 mm) from a true circle for 85 percent of the holes in a c ontiguous group, and not more than 1/16 inch (1.6 mm) for the remainder. Punch holes using a die with a diameter not exceeding that of the punch by more than 1/16 inch (1.6 mm). Ream and drill holes using twist drills and twist reamers. Wherever possible, direct the reamer by mechanical means. Sub-drill holes 3/16 inch (5 mm) less in diameter than the nominal diameter of the bolt, and ream the holes to size with the parts assembled, except: 513.20 385 A. The fabricator may sub -punch main material conforming to ASTM A 709/A 709M, Grade 36 (250) steel that is less than 3/4 inch (19 mm) thick, and Grade 50 (345) or 50W (345W) steel that is less than 5/8 inch (16 mm) thick.

513.20 High -Strength Steel Bolts, Nuts, and Washers . Provide high -strength

steel bolts, nuts, and washers conforming for all bolted connections including erection bolts for cross frames and lateral bracing to 711.09.

513.21 Welding. Perform welding b y the shielded metal -arc, submerged arc,

flux cored arc, or stud welding process. Only shielded metal arc (stick) welding is prequalified. All other welding processes require testing and approval by the Office of Materials Management. Consideration will be given to other methods of metal - arc welding if a written request is submitted to the Office of Materials Management. In other respects, the AASHTO/AWS Bridge Welding Code , as amended by Supplement 1011, shall govern the work. Post copies of the shop weldi ng procedures at each welding location. Weld only fracture critical and main members when the fabrication quality control specialist and inspectors are physically at the facility. The fabricator shall not perform fracture critical welding without prior sch eduling with the fabrication 513.22 390 quality control specialist and the inspector. The fabrication quality control specialist shall witness the minimum percentages specified in Supplement 1078 and shall check all welding processes. For non -fracture critical welds, the fabrication quality control specialist shall perform frequent inspections, and check all welding processes.

513.22 Stud Shear Connectors. Perform stud welding according to the

AASHTO/AWS Bridge Welding Code, as amended by Supplement 1011, and this subsection. In addition to the stud bend tests of Article 7.6.6.1 of the AASHTO/AWS Bridge Welding Code, perform bend tests of stud shear connectors at the start of each workday, when welding has been interrupted for an hour or more, when changing grounds, when changing weld settings, and when changing cable loop due to arc blow. Do not weld more than 500 studs without the welds being field bend tested in accordance with the specified procedure. The Contractor may leave in the bent position tested studs tha t show no sign of failure, as determined by the Engineer. Weld stud shear connectors to the top flanges of beams or girders after the steel has been erected and suitable scaffolding or deck forming has been provided. Studs may be welded to beam or girder w ebs, end dams, bearing plates, or to other secondary members and detail material in the shop. For galvanized structures with welded shear connectors, remove the galvanic coating by grinding at each connector prior to welding.

513.23 Threads for Bolts and P ins. Threads for pins shall conform to the

Unified Standard Series ANSI B1.1 -UNC (ANSI B1.13M) Class 2A (6g) for external threads and Class 2B (6H) for internal threads, except that pin ends having a diameter of 1 3/8 inches (35 mm) or more shall be thread ed 6 threads to the inch (4.23 mm/thread).

513.24 Shop Assembly. Remove paint, grease, oil, rust, loose mill scale, and

protruding edges or burrs from all contact surfaces. Unless waived by the Office of Materials Management, do not assemble and weld flang es and webs to form girders or other similar members and do not accomplish fabrication or assembly that interferes with the repair of a butt weld until the fabrication quality control specialist for the A rated fabricators or the inspector for B and C rate d fabricators examines and approves radiographs of all butt welds in the component parts. Perform fit -up work with the members assembled in unloaded positions as shown on the shop drawing layout required by 513.06. During shop assembly, adequately support members, especially at joints, to prevent misalignment or deflection and designate supports that prevent settlement during the fit -up, reaming or drilling of connections. The fabrication quality control specialist shall maintain records of the actual horiz ontal and vertical dimensions and relative positions of each assembly for each offset required by 513.06 and, upon request, furnish a copy to the inspector. Reposition members that become a part of two assemblies for the second assembly to the dimensions r ecorded for the first assembly. Using steel stamps, match -mark all connecting parts assembled in the shop for the purpose of reaming or drilling of holes for field connections or for fit -up of field welded connections before disassembly. Punch mark bearing centerlines. 513.25 391 Continuous beam and plate girders, including sections adjacent to hinged, pin connected, sliding, or rocker bearing joints, shall have at least three adjacent segments assembled, and holes reamed or drilled while assembled. Check the fit -up of field welded connections by similar shop assembly. Shop assemble longitudinal or transverse beams and girders that are either framed or connected by diaphragms and floor beams to check fit -up of connections to be field welded, or to ream or drill holes f or bolted connections. Assemble trusses in lengths of at least three abutting panels before drilling or reaming field connections. Include deck plates in the final shop assembly of bridges that involve railroad deck plates, even if welding of these deck pl ates takes place in the field. If the fabricator elects to use numerically controlled drilling or punching, the required assembly shall be performed as specified above. The Office of Materials Management will consider the Contractor’s written request to us e other methods of checking hole alignment and match marking. If the Office of Materials Management does not consider, or disapproves the fabricator’s proposed methods of assembly, perform the work according to 513.19 and 513.24. After fabrication, shop as semble deck expansion devices to check fit -up, straightness, and roadway cross -slope changes. Full width assembly is required with phased construction if expansion devices have interlocking fingers or have mechanical devices that require exact field alignm ent. The fabricator may fabricate part -width deck segments without the required shop assembly under the following conditions:

513.25 Nondestructive Testing. Nondestructive testing shall conform to the

AASHTO/AWS Bridge Welding Code , as amended by Suppleme nt 1011 and as specified below. As the Engineer directs, perform ultrasonic or radiographic inspection of field welded repairs in main members for thick scabs, deep kerfs or nicks, and similar gross flaws. Ensure that all examined welds and base metal adja cent to a welded joint conform to the quality requirements specified in 513.21. Submit radiographs, field sketches showing specific locations, lengths and depths of the repair, and two copies of the radiographic or ultrasonic technical reports to the Offic e of Materials Management for acceptance. Receive the Office of Materials Management’s 513.25 392 acceptance before performing construction activities making welds inaccessible for repair. The Contractor or fabricator shall notify the Department at least 48 hours bef ore performing nondestructive testing. Provide this notice even if specific hold or witness point inspections are not required by Supplement 1078. The Office of Materials Management has the final authority to accept welds and will resolve controversies reg arding the interpretation of radiographs, magnetic particle indications, or the acceptability of welds.

513.26 Shipping, Storage, and Erection. Repair or replace, at the discretion of

the Office of Materials Management, members damaged by improper handling, storing, or erec tion. During transportation, place adequate blocking between members to prevent movement and facilitate unloading. Unless reinforced by additional plates, angles, or other material bolted in place, do not use field connection holes for tie -down. Band toget her bearing components. Place material stored in the fabricating shop or in the field on skids or blocks to prevent the metal from contacting the ground. Place and shore girders and beams in an upright position for shipping, and field and shop storage. Field splice plates shall be bolted with temporary bolts, which shall be removed and replaced, when field splice plated are placed in their final position or shifted laterally with respect to their final position. Keep material clean and properly drained. Install bearing devices and anchorages according to Item 516. Thoroughly clean bearing surfaces and surfaces to be in permanent contact before the members are assembled in the field. Before erecting structural steel, completely bolt up field splices and conne ctions that started before steel erection. During erection, the Engineer will allow drifting to draw the parts into position, but do not enlarge the holes or distort the metal. Install drift pins and bolts according to 513.20. Fill at least three -fourths of the holes with completely tightened bolts in splices and connections subject to construction loads during erection. Complete permanent fastening of steel truss tension chord members before removing falsework. Permanently fasten compression chord members after the span is released sufficiently from the falsework to bring the compression chord joints into full bearing. Properly regulate and maintain elevations of panel points and ends of floor beams until the falsework is removed. Do not enlarge the holes of splices and connections between segments or elements of main members without approval by the Office of Materials Management. Adjust structures to the correct alignment and to the marked bearing centerlines before beginning permanent fastening. Do not pe rmanently fasten cross frames and lateral bracing in continuous beam or girder spans until completing main connections in adjacent spans; however, install sufficient bracing to maintain structural stability. For erection bolts used to fasten cross frames, use not less than 5/8-inch (16 mm) diameter, and fully tighten bolts according to 513.20. 513.27 395 Erect end cross frames and end dams in a manner that ensures bearing parts remain in bearing contact. Permanently fasten all intermediate cross frames before deck pla cement begins. The webs of primary members shall be plumb before deck placement begins.

513.27 Shop Coating. For steel surfaces specified to be coated according to

Item 514, apply a prime coat in the shop.

513.28 Cleaning ASTM A 709/A 709M, Grade 50W (345W ) Steel. Before the

new steel is shipped, solvent clean, where necessary, all surfaces of ASTM A 709/A 709M, and Grade 50W (345W) steel that are to be left unpainted to remove all traces of asphalt cement, oil, grease, diesel fuel deposits, chalk, paint ma rks, and other soluble contaminants according to SSPC -SP 1 Solvent Cleaning. QCP #1 and QCP #2 shall apply according to Item 514. Shop blast unpainted Grade 50W material to SSPC -SP 6, commercial blast. QCP #3 shall apply according to Item 514. After placin g superstructure concrete, clean, where necessary, the exterior surface and bottom flanges of all fascia beams or girders that are to be left unpainted to remove all traces of asphalt cement, oil, grease, diesel fuel or petroleum deposits, concrete, and ot her contaminants. Do not use acid for cleaning.

513.29 Method of Measurement. The Department will measure Structural

Steel Members on a lump sum basis or by the number of pounds (kilograms). If payment is per pound (kilograms), submit weight computations t o the Office of Materials Management based upon the accepted shop drawings. Deduct waste material, removed by burning, cutting, machining, holes, etc., but include groove weld bevels. Include the weight of all permanent fasteners, shop fillet welds, other metals and preformed bearing pads. Exclude the weight of paint or galvanized coatings. Exclude thickness or weight of members exceeding the plan requirements (due to overweight or other cause), unless authorized by the Department. As an option, measure and record the weight of structural members before painting in the presence of the inspector. Use the following unit weights for computations. lb/ft³ (kg/m ³) Steel, cast steel, and deposited weld metal 490 (7850) Cast iron 450 (7210) Phosphor or leaded bronze 550 (8810) Lead 710 (11370) Preformed bearing pads 710 (11370) The Department will measure Welded Stud Shear Connectors by the number of each installed and accepted.

513.30 Basis of Payment. If the fabricator’s proposed methods of assembly

with numerically controlled drilling or punching fail to produce specified results and the Office of Materials Management directs the Contractor to perform work, as according to 513.19 and 513.24, the Department will not pay for this work. 513.30 396 For steel surfaces specified to be coated according to Item 514, the cost of applying a prime coat in the shop is incidental to the bid for structural steel. The Department will not pay for repairing or replacing members damaged by improper handling, storing, transportation, or erection. The Department will pay for the accepted quantities at the contract prices as follows: Item Unit Description 513 Lump Sum Structural Steel Members, Level UF 513 Lump Sum Structural Steel Members, Level 1 513 Lump Sum Structural Steel Members, Level 2 513 Lump Sum Structural Steel Members, Level 3 513 Lump Sum Structural Steel Members, Level 4 513 Lump Sum Structural Steel Members, Level 5 513 Lump Sum Structural Steel Members, Level 6 513 Pound (Kilogram) Structural Steel Members, Level UF 513 Pound (Kilogram) Structural Steel Members, Level 1 513 Pound (Kilogram) Structural Steel Members, Level 2 513 Pound (Kilogram) Structural Steel Members, Level 3 513 Pound (Kilogram) Structural Steel Members, Level 4 513 Pound (Kilogram) Structural Steel M embers, Level 5 513 Pound (Kilogram) Structural Steel Members, Level 6 513 Each Welded Stud Shear Connectors ITEM 514 PAINTING OF STRUCTURAL STEEL

514.01 Description

514.02 Materials

514.03 Superintendent

514.04 Quality Control

514.05 Testing Equipment

514.06 Work Limitations

514.07 Protection of Persons and Property

514.08 Pollution Control

514.09 Safety Requirements and Precautions

514.10 Inspection Access

514.11 Job Site Visual Standards

514.12 Quality Control Point Photographic Verification and

Docum entation

514.13 Surface Preparation

514.14 Washing Shop Primer

514.15 Handling

514.16 Mixing and Thinning

514.17 Coating Application

514.18 Removing Fins, Tears, or Slivers

514.19 Caulking

514.20 Dry Film Thickness 514.01

397 514.21 Final Inspection

514.22 Repair Pro cedures

514.23 Method of Measurement

514.24 Basis of Payment

514.01 Description . This work consists of cleaning and painting all steel

surfaces.

514.02 Materials. On existing steel, apply a three -coat paint system consisting

of an organic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat. The coating system shall conform to 708.02 . On new steel, apply a three -coat pain t system consisting of an inorganic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat. The prime coat shall conform to 708.01 , and the intermediate and finish coats shall conform to

708.02 Supply the intermediate and finish coats from the same manufactu rer. The

Contractor is responsible for ensuring the compatibility of the intermediate and finish coats with the prime coat. For caulking, use a single pack moisture cured polyurethane based material, which will not shrink , or sag capable of filling voids up to 1 inch (25 mm) wide . Only material that is listed on the OMM Qualified Product List website may be used.

514.03 Superintendent . In addition to the requirements of 105.06 , the

Superintendent must successfully complete a Bridge Painting pre -qualification course and training offered by the Department. The course must have been completed within the past four years and an individual course certificate must have been received by the Superintendent. Present certificate to the Engineer prior to commencing work. No work is permitted unless the Superintendent provides a valid course certificate.

514.04 Quality Control. Quality control consists of designating quality control

specialists to control the quality of work in each phase established by Quality Control Poi nts (QCPs). Control quality by inspection, tests, and cooperation with inspection and testing performed by the Engineer and inspector.

514.05 Testing Equipment. For the project duration, provide the Engineer or

inspectors with the test equipment listed below for the type of work at each work site with ongoing work. With the exception of the recording thermometer, the fabricator shall provide its quality control specialist s with the test equipment listed below. The Contractor and fabricator shall maintain all testing equipment in good working order, and provide documentation or certification of calibration from the manufacturer. If the Contractor or Fabricator and the Engin eer’s inspector are using different test equipment, the Contractor or Fabricator and the Engineer’s inspector will perform side -by-side testing and compare results. If the difference between the Department’s and Contractor’s or Fabricator’s tests results, such as blast profile, dry film thickness, temperature, dew point and relative humidity, are greater than 1%, the Contractor or Fabricator and the Engineer will determine the reason for the differences and make necessary adjustments .

514.06 Work Limitations. Apply the prime coat to new structural steel inside

permanent buildings at the fabricator’s facility. If inside permanent buildings, the fabricator may perform year -round abrasive blasting and painting. Perform abrasive blasting and painting in the field from April 1 to October 31. The Department will not issue a time extension due to adverse weather during the month of April. The plans or other Contract Documents may require additional wor k limitations for specific bridges or projects.

514.07 Protection of Persons and Property. Collect, remove, and dispose of

all rubbish, buckets, rags, or other discarded materials and leave the job site in a clean condition. Except for deck bottoms and backwalls which have not been sealed or a re not to have a sealer applied, protect all portions of the structure, that are not to be painted from damage or disfigurement by splashes, spatters, and smirches of paint. If the Contractor causes any damage or injury to public or private property, the Contractor shall restore the property, to a condition similar or equal to the condition existing before the damage or injury.

514.08 Pollution Control. Comply with pollution control laws, rules, or

regulations of Federal, State, or local agencies and requir ements of this specification.

514.09 Safety Requirements and Precautions. Comply with the applicable

safety requirements of the Ohio Industrial Commission and OSHA . Provide Safety Data Sheets ( SDS) at the preconstruction meeting for all paints, thinners, and abrasives used on this project. Do not b egin work until submitting the SDS to the Engineer.

514.10 Inspection Access and L ighting . In addition to the requirements of

105.10 , furnish, erect, and move scaffolding and other appropriate equipment to

allow the insp ector and the Engineer the opportunity to closely observe all affected surfaces during all phases of the work and for at least 10 workdays after completely painting each structure to allow for the Final Inspection according to 514.21 . Provide artificial lighting as necessary to supplement natural light with a minimum of 30 foot candles (325 LUX) at the surface of the steel for inspection, cl eaning, and painting. Prevent glare that interferes with traffic, workers and inspection. Submit to the Engineer for information, complete details of the inspection access that complies with the applicable safety requirements of The Ohio Industrial Commiss ion and OSHA. The details shall be reviewed, signed, stamped and dated by an Ohio registered Professional Engineer certifying that they meet these requirements. Maintain the in -place inspection access equipment employed during original painting activities or provide alternate inspection equipment such as platform lifts, bucket trucks, snooper trucks, or equivalent as approved by the 514.10 404 Engineer. If scaffolding, or any hanger attached to the scaffolding, is supported by horizontal wire ropes, or if scaffolding is directly under the surface to be painted, comply with the following requirements:

514.11 Job Site Visual Standards. Before starting abrasive blasting, establish

job site visual standards by preparing a test section, subsequent test sections, and by using photographs of approved test sections. Use job site visual standards and S SPC- VIS 1 standard for blasting. The Contractor or fabricator shall prepare an approximately 20 to 30 square foot (2 to 3 m ²) test section from a representative area on the first structure to be painted. After the Engineer or Inspector and the Contractor or fabricator agree the test area was blast cleaned to the requirements of the Contract Documents, photograph the test section and check the steel surface for the proper profile. After the Engineer or Inspector approves the test section and the job site visual standards are documented by photographs and replica tape, the Contractor or fabricator may start abrasive blasting. The quality control specialists and Engineer or Inspector will use the job site visual standards (photographs), the Plan, Specification and requirements to determine acceptance of blast cleaning procedures. In all cases of dispute, the SSPC -VIS 1 standard shall govern. If the Contractor, Engineer, Inspector, or fabricator believe the initial test section does not establish the proper visu al standard for a different structure another test section on the different structure may be performed.

514.12 Quality Control Point Photographic Verification and

Documentation. The Engineer or Inspector will take a sufficient number of photographs to document the condition of the work at Quality Control Points 3, 4 and 11.

514.13 Surface Preparation.

514.14 Washing Shop Primer (QCP #7) . Wash shop primed structural steel

after it is erected and the concrete deck is placed and within 30 days of applying the intermediate coat. Wash the steel with potable water. Use equipment capable of delivering the water at a nozzle pressure of at least 1000 pounds per square inch (7 MPa) and at a rate of not less than 4 gallons (15 L) per minute. The Contractor shall provide the Engineer 514.15 410 with eq uipment specifications that verify both the delivery pressure and rate. Provide gauges on the equipment to verify the pressure during operation. Hold the nozzle a maximum of 12 inches (300 mm) from the surface being washed. The surface is clean when clear rinse water runs off the structure. After rinsing the surface, inspect for remaining dirt and rewash dirty areas until clean.

514.15 Handling . Deliver all paint and thinner in original unopened containers

with labels intact. The Engineer or Inspector will accept containers with minor damage provided the container is not punctured. Thinner containers shall be a maximum of 5 gallons (19 L). Before use, provide the Engineer with shipping invoices for all painting materials used on the Project. Supply container s of paint and thinner with labels clearly marked by the manufacturer to show paint identification, component, color, lot number, stock number, date of manufacture, and information and warnings as may be required by Federal and State laws. Store paint at t he temperature recommended by the manufacturer and in a storage facility that prevents theft. Provide thermometers capable of monitoring the maximum high and low temperatures inside the storage facility. Before opening paint or thinner containers, check th e labels to ensure the proper container is opened and the paint has not been stored beyond its shelf life. Do not use paint that exceeded its shelf life. Do not open containers of paint and thinner until required for use and then open the oldest paint of e ach kind first. Solvent used for cleaning equipment is exempt from the above requirements. Do not use paint that has livered, gelled, or otherwise deteriorated during storage. Properly dispose of unused paint and paint containers.

514.16 Mixing and Thinnin g. Thoroughly mix all ingredients immediately

before use with a high shear mixer (such as a Jiffy Mixer). Do not mix paint using paddle mixers, paint shakers, or an air stream bubbling under the paint surface. After mixing, carefully examine the paint for uniformity and to ensure that no unmixed pigments remain on the bottom of the container. Before use, strain the paint through strainers that remove skins or undesirable matter but not pigment. Except for primer, mix paint as necessary during application to maintain a uniform composition. Continuously mix primer using an automated agitation system. Do not use hand -held mixers for primer paints. Do not add thinner to the paint without the Engineer’s or Inspector’s approval, and only add thinner if necessary f or proper application as recommended by the manufacturer’s printed instructions. In the Engineer’s or Inspector’s presence, slowly add the amount of thinner recommended and supplied by the manufacturer to the paint during the mixing process. Do not mix oth er additives into the paint. Add catalysts, curing agents, or hardeners that are in separate packages to the base paint only after thoroughly mixing the base paint. With constant agitation, slowly pour the proper volume of catalyst into the required volume of base. Do not pour off liquid that has separated from the pigment before mixing. Use the mixture within the pot life specified by the manufacturer and dispose of unused portions at the end of each workday. 514.17 411 514.17 Coating Application

514.18 Removing Fins, Tears, or Slivers (QCP #6) . Use a grinder to remove

all fins, tears, slivers, or any other burred or sharp edges that become evident after applying the prime coat. Retexture ground surfaces to produce a profile from 1.5 to 3.5 mils (40 to 90 μm) and reprime ground surfaces before a pplying the intermediate coat. The Contractor may begin removing fins, tears, and slivers after blasting and before priming. Temperature and weather restrictions do not apply to removing fins, tears, and slivers, but do to applying the prime coat.

514.19 Caulking (QCP #9). After the intermediate coat cures and before

applying the finish coat, caulk gaps or crevices up to 1/2 inch ( 13 mm) wide. Follow the manufacturer’s recommendations for curing before applying the finish coat . 514.20 416 514.20 Dry F ilm Thickness (QCP #5, #8, and #10). Determine prime coat thickness; prime and intermediate coat thickness; and prime, intermediate, and finish coat thickness using a Type 2 magnetic gage as follows: Measure paint thickness at separate, evenly spaced, spot measurement locations over each 100 square feet (9 m²) of area of structural steel. Locate five spot measurements on each of the following locations: top flanges; bottom flanges; webs; cross bracing; stiffeners; etc. At each spot location, take three gag e readings of either the substrate or the paint. Move the probe 1 to 3 inches (25 to 75 mm) for each new gage reading. Discard an unusually high or low gage reading that is not consistently repeated. The spot thickness measurement is the average of the thr ee gage readings. The average of five spot measurements for each location in the 100 square foot (9 m²) area shall not be less than the specified thickness. No single spot measurement area shall be less than 80 percent of the specified minimum thickness n or greater than 150 percent of the maximum specified thickness when organic zinc is applied and 120 percent of the maximum specified thickness when inorganic zinc is applied. Any one of three readings which are averaged to produce each spot measurement, may under run or overrun by a greater amount. Take five spot measurements per location for each 100 square foot (9 m²) area as follows:

514.21 Final Inspection

514.22 Repair Procedures. Remove paint and correct defects or damaged

areas, including areas damaged by welding, and in areas that do not comply with the requirements of this specification. Correct defects and damaged areas using the same paint as originally applied except the Engineer may approve using organic zinc to repair inorganic zinc in the field. Retexture the steel to a near white condition and a profile between 1.5 to 3.5 mils (40 to 90 μm) . Measure the profile immediately before applying the prime coat to ensure the profile is not destroyed during the feathering procedure. See 514.13 .C. Feather the existing paint to expose a minimum of 1/2 inch (13 mm) of each coat. During the reapplication of the paint, apply paint as follows:

514.23 Method of Measurement. The Department will measure Surface

Preparation of Existing Structural Steel and Field Painting of Existing Structural Steel Prime Coat by the number of square feet (square meters) of structural steel painted or on a lump sum basis. The Department will me asure Field Painting 514.24 420 Structural Steel, Intermediate Coat and Field. Painting Structural Steel, Finish Coat by the number of square feet (square meters) or pounds (kilograms) of structural steel painted, or on a lump sum basis. The Department will determine the number of pounds (kilograms) of new structural steel painted by the accepted pay weight of the new structural steel. For steel beam and steel girder bridges, the Department will determine the surface area by taking a nominal measurement of the beams ( i.e., two times the beam depth plus three times the flange width). In addition to this nominal measurement, the Department will add a percentage to account for incidentals such as cross frames, bearing assemblies, stiffeners, expansion joints, scuppers, et c. It is not necessary for the Engineer or Inspector to field measure every detail of the bridge to verify quantities. If there is a quantity dispute, exact field measurements of all painted surfaces and calculations will govern over the above percentage t o account for incidentals. For extremely complex bridges, such as trusses, the Department will pay for painting on a lump sum basis. The Department will measure grinding fins, tears, slivers on existing structural steel by the number of man hours expended by the workers actually doing the grinding and will include the time when the workers are performing grinding and repairing prime coat and not limited to only the actual grinding duration (i.e., the Department will include all hours of the workers when ass igned to grinding regardless of actual grinding time). The Department will not measure grinding fins, tears, and slivers on new steel but will consider it incidental to unit price for the new steel.

514.24 Basis of Payment . The Department will pay for accepted quantities at

the Contract prices as follows: The Department may consider paint as eligible for payment for material on -hand as specified in 109.10 , however, only paint that the Contractor can prove to the Engineer will be used during the construction season is eligible for payment. The Contractor shall provide the Engineer calculations indicating the total square feet (square meter ) of steel to be painted during the construction season. The Contractor shall also provide calculations showing the total number of gallons (liters) required. If the Contractor causes damage or injury to public or private property, the Department will not pay for restoring the property to its original condition. The Department will not pay for repairing adjacent coatings damaged during the blasting operation. The Department will not pay for removing and replacing an area of coating because a spot or maximum average thickness exceeds the maximum spot thickness. The Department will not pay for additional testing required by any hauler, treatment facility, disposal facility or landfill. The Department will pay for caulking under Field Painting Structural Steel, Intermediate Coat. 514.24 421 The Department will pay for final inspection access, test area preparation and test area repair at each selected area under Final Inspection Repair. The Department will not pay for accessing, inspecting, and repairing areas that are not found to be in conformance with the specifications an d pertinent contract documents. All other requirements of this specification are considered incidental to the work. Item Unit Description 514 Square Foot Surface Preparation of (Square Meter) Existin g Structural Steel Lump Sum 514 Square Foot Field Painting of Existing (Square Meter) Structural Steel, Prime Coat Lump Sum 514 Square Foot Field Painting Structural (Square Meter) Steel, Intermediate Coat Lump Sum, Pound (Kilogram) 514 Square Foot Field Painting Structural (Square Meter) Steel, Finish Coat Lump Sum, Pound (Kilogram) 514 Man Hour Grinding Fins, Tears, Slivers on Existing Structural Steel 514 Each Final Inspection Repair 514 Square Foot Shop Painting and Field Touch -Up of (Square Meter) Structural Steel Lump Sum Pound (Kilogram) ITEM 515 PRESTRESSED CONCRETE BRIDGE MEMBERS

515.01 Description

515.02 Fabricator Approval Procedure

515.03 Levels of Fabricator Qualification

515.04 General

515.05 Fabricator Documentation Responsibility

515.06 Shop Drawings

515.07 Pre-Fabrication Meeting

515.08 Materials

515.09 Materials Approval

515.10 Casting Beds

515.11 Weather Conditions During Production

515.12 Equipment

515.13 Inspection Facilities

515.14 Construction Me thods

515.15 Concrete

515.16 Release of Prestressing Strands 515.01

422 515.17 Fabrication tolerances

515.18 Prestressed Member Acceptance and Repair

515.19 Handling, Storage, Transportation, and Erection

515.20 Safety Requirements

515.21 Method of Measurement

515.22 Basis of Payment

515.01 Description. This work consists of preparing shop drawings, furnishing

and manufacturing prestressed concrete bridge members, testing, fabricator performed quality control, documentation, shop coating, and handling, transporting, storing, and erecting prestressed concrete bridge members. Prepare shop drawings and erect prestressed concrete bridge members, according to Item 501 and the additional requirements specified below. Shop coating shall conform to Item 512.

515.02 Fabricato r Approval Procedure. Select fabricators that are pre -

qualified and evaluated by the Office of Materials Management (OMM) according to Supplement 1079 and listed by the Department before the Contract letting Date.

515.03 Levels of Fabricator Qualification. There are three levels of fabricator

qualification. OMM will classify each fabricator at the highest level of fabrication it is qualified to perform . Level Description of Capabilities 1 Straight strand prestressed box beam members 2 Straight strand prestressed I -beam members 3 Draped strand prestressed I -beam members

515.04 General. Produce all members according to Item 511, except as

otherwise specified herein.

515.05 Fabricator Documentation Responsibility. The fabricator shall keep

and maintain records for each project bid line number concerning:

515.06 Shop Drawings. Provide shop drawings conforming t o 501.04 and the

following requirements. Include all details, dimensions, dimensional tolerances, and size of materials, lifting devices, inserts, reinforcing steel supports, fabricator incorporated reinforcing, piece mark diagrams for field connection and erection of any steel and all prestress members, and all other information necessary for the complete fabrication and erection of the prestressed members. Show all items that will be incorporated into each prestressed member. Provide the detensioning proc edure and pattern conforming to 515.16.

515.07 Pre-Fabrication Meeting. At least 3 days after the Department receives

shop drawings, conduct a pre -fabrication meeting at the fabricator’s facilities, or another location agreed to by all parties. As part of the pre -fabrication meeting request, provide a initial fabrication schedule for the prestressed beam project including:

515.08 Materials. Furnish materials conforming to:

Reinforcing steel ................................ .......................... 509 Concrete ................................ ................................ .. 515.15 515.09 424 Portland cem ent ................................ ... 701.01 thru 701.09 Aggregate * ................................ ............................ 703.02 Air-entraining admixture ................................ ........ 705.10 Chemical admixtures for concrete .......................... 705.12 Prestressing steel ................................ .................... 711.27 Transverse tie rods ................................ ................. 711.01 Welded wire reinforcement ................................ .... 709.12 * For fine aggregate, use natural sand for members without a separate wearing course. Modify coarse aggregate as follows: Do not allow more than 0.4 percent deleterious materials. For gradation, use No. 6, 67, 68, 7, 78, or 8 size coarse aggregate.

515.09 Materials Approval. The fabricator shall control, test, and validate

material requirements for all materials either incorporated into the prestressed fabricated item or supplied under Item 515 as component parts to the fabricated items. The fabricator shall provide Supplement 1079 documentation to the in spector at the time of final inspection. The Department will not sample materials at the fabricator’s shop for Department approval. The Department will randomly sample materials to verify the fabricator’s performance.

515.10 Casting Beds. Use steel or conc rete casting beds set above grade to

ensure the beds remain above the accumulation of water resulting from production and curing operations. Design beds and abutments capable of safely resisting all forces applied to them without appreciable movement or de flection. These forces include compression and eccentric forces due to end -jacking operations, forces at hold down points when draped strands are used, and downward forces due to the dead weight of the members.

515.11 Weather Conditions During Production. Make temperature change

adjustments to initial strand tensioning according to PCI Quality Control Manual 116.

515.12 Equipment. Provide hydraulic jacks of sufficient capacity and stroke to

tension strands. Use either single or multiple strand tensioning. Provide tensioning jacks equipped with automatic cutoff valves and equipped with 6 inch (150 mm) minimum diameter gages that provide readings at 500 pound (2 kN) increments. Calibrate gages for the jacks w ith which they are to be used. Have a graph or table showing the calibration available for the inspector. Calibrate jacks according to a method acceptable to the Laboratory at least every 6 months or as required by the Director. Maintain calibration docume ntation as part of the project’s QC inspection records. Design the jacking system to ensure uniform stress in all strands. If simultaneously tensioning multiple strands, use approved types of dynamometers to equalize the initial stress on all strands befor e applying the full tensioning load with the master jack Provide dynamometers with sufficient capacity to ensure that the desired readings are in the middle to upper range .

515.13 Inspection Facilities. The fabricator shall provide the inspector office

accommodations conforming to the following requirements:

515.14 Construction Methods. Use metal forms capable of producing members

within the tolerances shown on the plans. Forms made of material other than meta l may be used for bulkheads and voids and may be used for a single project for prestressed members requiring non -standard forms. Ensure that the surfaces of the forms in contact with the concrete are smooth and the joints between panels are tight. The sof fit form shall have a plane surface at right angles to the vertical axis of the members and have the two bottom edges beveled 3/4 inch (19 mm) with a triangular strip built into the forms. Increase the length of the forms for elastic shortening and normal concrete shrinkage, and design the forms to accommodate this movement . 515.15 426 Provide water -resistant formwork for box beam voids constructed of a material that resists breakage and deformation during placement of concrete. Provide form material that does not exc essively increase the dead load of the beams. Prevent the release agent from contacting the prestressing strands or reinforcing steel. Install and assemble reinforcing steel according to the approved shop drawings. If authorized, weld reinforcing cages usi ng welders qualified to AWS D1.4. Do not weld epoxy coated or galvanized reinforcing steel unless approved by Office of Material Management. Repair all coating areas damaged by welding according to the coating manufacturer’s instructions. Reject reinforcin g steel with a loss of cross - section of reinforcing caused by welding. Provide a protective covering for the prestressed steel from the elements until the strand is pulled into the bed. Accurately place strands in the positions shown on the shop drawings. Do not use strands with kinks, bends, nicks, broken wires, scale, loose rust, or other defects. The fabricator may use slightly rusted reinforcing steel provided the rust is not sufficient to cause visible pits. Before placing the concrete, carefully clea n the strands of all dirt, grease, oil, or other foreign matters. Do not splice strands within a member. Tension strands uniformly to the stress indicated on the shop drawings. If multiple stands are stressed simultaneously, use dynamometers to equalize th e initial stress on all strands before applying full tension load with master jack. Measure the required stress in the strands using the calibrated jacking equipment gages, and check the measured stress by the elongation of the strands. If the stress from the gages and the measured elongation are not within a 5 percent tolerance of the design, stop stressing the strands and determine the reason for the differences. The quality control specialist shall keep a record of the jacking forces and elongations of a ll strands . Secure the strands by suitable anchorage devices capable of developing at least 85 percent of the ultimate strength of the strands. The anchorage shall not allow the strand to slip after the tensioning operation. If using draped strands, the lo ss of stress due to friction shall not exceed 5 percent. Tension the strands at both ends. The quality control specialist shall measure the loss due to friction by a procedure approved by the Office of Material Management. Place hold -down points within 3 i nches (90 mm) of the locations shown on shop drawings and within 12 inches (0.3 m) of the locations shown on the plans. Unless otherwise shown in the plans, do not install inserts or holes in the beam web within a distance of 1.5 times the beam height from the end of the beam.

515.15 Concrete . The fabricator shall provide concrete mix designs to Office of

Material Management. The submittal will include:

515.17 Fabrication Tolerances. Construct all members to conform to the

following tolerances. TABLE 515.16 -1, BEAM DIMENSIONAL TOL ERANCES Description Box Beam I Beam Length of beam ±1/8" per 10 ft (1 mm/m) max ±3/4" (19 mm) ±1/8" per 10 ft (1 mm/m) max ±1" (25 mm) Depth of beam ±1/4" (6 mm) -1/4" (6 mm) +1/2" (13 mm) Depth of I beam flange including fillets N/A ±1/4" (6 mm) Beam (box)/Flange (I) Flange Width ±1/4" (6 mm) -1/4" (6 mm) +3/8" (10 mm) Flange Thickness excluding fillets

515.18 Prestressed Member Acceptance and repair . Throughout the

fabrication process reject all prestressed members not meeting specification requirements. For all rejected members provide the Department with a complete description of the rejection, and unless waived by the Director, an Ohio registered p rofessional engineer’s written evaluation of the criticalness of the rejection and the professional engineer’s proposed repair method that will repair the rejected member to an acceptable condition. The Department will determine the acceptability of the member and the repair procedure. If acceptable, the fabricator will only make repairs witnessed by the Department’s inspector unless waived by Director. 515.19 431 Use the Precast/Prestress Concrete Institute’s Manual for the evaluation and repair of Precast, Prestres sed Concrete Bridge Products MNL -137-06 as a general guide. The Department will not accept for shipping, prestressed members with measured camber exceeding the Design Camber (Dt), used to establish the seat elevations, according to 511.07, by more than the Sacrificial Haunch thickness, until a corrective work plan has been approved by the Engineer. The plan shall be signed, sealed and dated by an Ohio Registered Engineer and shall include all revised plan information necessary to place the deck to the plan thickness. If the prestressed members are acceptable, exclusive of the deviation from Design Camber, the Department will pay for all costs incurred resulting from measured camber exceeding Design Camber calculated for the actual beam age at the time of dec k placement, as Extra Work, 109.05.

515.19 Handling Storage, Transportation, and Erection. Handle, store,

transport, and erect the members in an upright position. The direction of support reactions during storage and transportation shall be the same as the member will experience in its in -service position. Do not ship prestressed members until the concrete obtains its 28 -day design strength and the inspector’s approval. Provide at least 30 inches (762 mm) horizontally between each beam for inspection. Provi de at least 8 inches (200 mm) of vertical clearance from the bottom. Use storage support locations as close as practical to the in -service support locations. During storage, provide unyielding horizontal supports and bracing capable of maintaining the memb ers in a vertical position. Transportation support locations shall be the sole responsibility of the fabricator with respect to member stresses and safe delivery to the job site . Obtain the Director’s written approval to transport the members in a positio n other than vertical ., Provide lifting devices capable of withstanding the required loads to lift and erect the members. During erection, accurately place the prestressed beams on their bearings to ensure a uniform load on all bearings. When shifting a m ember, lift the member up completely off of its bearings. Temporarily brace the first I -beam erected to its substructure support units in the vertical position before releasing the beam from the crane. Tie each subsequent I - beam to the previously braced b eam(s). Provide bracing after erection adequate to prevent sliding, tipping, or other movement that may result from high winds, creeping down the grade, or other causes, until placement of the diaphragms. Within any one day erect and brace at least 2 adjac ent members in any one span before suspending operations for the day. Place box beams to ensure a correct fit of the keyways and to ensure proper grouting of the keyways. After placing the beams and installing tie devices, fill the longitudinal keyways usi ng non -shrink keyway grouts, 705.22, approved by OMM. Mix, install, and cure the grout according to the manufacturer’s published recommendations to obtain a design compressive strength of 5000 pounds per square inch (34.5 MPa). 515.20 432 Do not allow vehicular load on an individual prestressed concrete box beam until the grout in the keyway obtains the specified design strength of 5000 pounds per square inch (34.5 MPa). At the Director’s discretion, repair or replace members damaged by improper handling, storage, tra nsportation, or erection.

515.20 Safety Requirements. Provide effective safety measures to prevent

injuries to personnel due to breakage of strands or failure of anchorage devices during the tensioning operations. Provide adequate protection and assure the OMM inspector can perform inspection of beams and manufacturing processes. The Department inspector will report any inadequate safety precautions to the plant QCS and to OMM if fabricator remedial action is not taken. OMM inspectors will follow safety rul es established by the fabricator, at a minimum. Where fabricator safety rules interfere with the inspectors’ duties, the process should be altered to allow the inspections to be performed while maintaining the required level of safety.

515.21 Method of Measurement. The Department will measure Prestressed

Concrete Bridge Members by the number of members. The Department will measure the intermediate diaphragms by the number of each placed.

515.22 Basis of Payment. Payment for prestressed concrete beams inc lude all

inserts, sleeves, fittings, reinforcing steel fully or partially encased in the members, threaded rods, embedded inserts, embedded bearing sole plates, temporary bracing, fixed anchor dowels, and all transverse tie rods necessary to complete this work . The Department will consider all costs associated with all structural steel, including bolts, nuts, washers and plate washers for steel intermediate diaphragms, as well as concrete and reinforcing steel for cast -in-place concrete intermediate diaphra gms as incidental to the intermediate diaphragms . The Department will pay for expansion joint end diaphragms, semi -integral diaphragms, pier diaphragms, bearing load plates , bearing pads, and other expansion materials, separately . The Department will not pay for repaired or replaced members damaged by improper handling, storing, transporting, or erecting. The Department will pay for accepted quantities at the contract prices as follows: Item Unit Description 515 Each Prestressed Concrete Non - Composite Box Beam Bridge Members, Level 1 515 Each Prestressed Concrete Composite Box Beam Bridge Members, Level 1 515 Each Straight Strand Prestressed Concrete Bridge I-Beam Members, Level 2 515 Each Draped Str and Prestressed Concrete Bridge I-Beam Members, Level 3 515 Each Intermediate Diaphragms 516.01 433 ITEM 516 EXPANSION AND CONTRA CTION JOINTS JOINT SEALERS AND BEARING DEVICES

516.01 Description

516.02 Fabrication

516.03 Coating

516.04 Materials

516.05 Expansion and Contraction Joints

516.06 Joint Sealers

516.07 Bearing Devices

516.08 Method of Measurement

516.09 Basis of Payment

516.01 Description. This work consists of fabricating, assembling,

constructing, coating, and installing expansion and contra ction joints, vertical extension of structural expansion joints, joint sealers, or bearing devices of the type and size specified.

516.02 Fabrication. Fabricate metal joint armor and metal bearings according

to Items 513. Select a fabricator that is at lea st pre -qualified at level SF. The Department will base final acceptance of fabricated members on the Engineer’s approval that the fabricated items that can be successfully incorporated into the structures. Submit mill test reports for structural steel, ste el castings, bronze, and sheet lead certified according to 501.06.

516.03 Coating. Coat exposed steel bearings according to Items 513 and 514

that are to be attached to structural steel. Galvanize bearings according to 711.02 that are to be attached to concrete beams. Coat metal parts of expansion joints with metalized 100 percent zinc wire. Prepare the surface to be coated and apply coating as required by The Society of Protective Coatings SSPC -CS-23.00(1). Apply coating to a minimum thickness of 6 mils. Repair metalized coatings damaged during fabrication by removal of the damaged coating and reapplication as specified above. Repair metalized or galvanized coatings damaged during shipping, construction, or field welding according to 711.02.

516.04 Mater ials. Furnish materials conforming to:

Structural steel ................................ ............................. 513 Bearing bolts and anchor rods ................................ . 711.10 Painting ................................ ................................ ........ 514 Joint sealer, hot applied ................................ .......... 705.04 Preformed elastomeric compression stager ............. 705.11 Neoprene Sheeting ................................ .................. 705.13 Steel castings ................................ .......................... 711.07 Sheet copper ................................ ........................... 711.15 Bronze ................................ ........... 711.16, 711.17, 711.18 Sheet lead. ................................ ............................... 711.19 Preformed bearing pads ................................ .......... 711.21 Elastomeric bearings ................................ ............... 711.23 516.05 434 Preformed fillers ................................ ..................... 705.03 Swedged anchor bolts or bars* ............................... 711.10 Non-Shrink,Non -Metallic Grout ………………….705.20 * Fabricated by deforming a minimu m of 20 percent of the embedded bolt surface with deformations whose radial dimensions are 15 to 20 percent of the bar diameter.

516.05 Expansion and Contraction Joints. Ensure that expansion joints are

completely open for the dimension specified for thei r full length. Remove stones, forms, or other materials that interfere with expansion. Finish the surface adjacent to preformed expansion joints to a smooth, uniform surface. Use methods that do not interfere with the free compression of the joint material to anchor the expansion joint materials. The joint material shall neatly fill the space, and have a uniform thickness for the full extent of the joint. For Integral and Semi -Integral Abutment Expansion Joint Seals, install a 3 foot wide neoprene sheet for waterproofing of the backside of the joint between the integral backwall and the bridge seat at locations shown in the plans. Secure the neoprene sheeting to the concrete with 1 1/4 inch by #10 gage (length × shank diameter) galvanized button head spikes through a 1 inch outside diameter, #10 gage galvanized washer. Maximum fastener spacing is 9 inches. Use of other similar galvanized devices, which will not damage either the neoprene or the concrete, will be subject to the approval of the Engineer. Center the neoprene strips on all joints. For horizontal joints, secure the horizontal neoprene strip by using a single line of fasteners, starting at approximately 6 inches from the top of the neoprene strip. For the vertical joints secure the vertical neoprene strip by using a single vertical line of fasteners, starting at approximately 6 inches from the vertical edge of the neoprene strip nearest to the centerline of roadway. For vertical joints, install two additional fasteners at 6 inches, center to center, across the top of the neoprene strip on the same side of the vertical joint as the single vertical row of fasteners is located. The vertical neoprene strips shall completely overlap the horizontal strips. Lap lengths of the horizontal strips that are not vulcanized or adhesive bonded, shall be at least 1 foot in length, or 6 inches in length if the lap is vulcanized or adhesive bonded. No laps are acceptable in vertically installed neoprene strips. The neoprene sheeting shall be 3/32 inch thick general purpose, heavy -duty neoprene sheet with nylon fabric reinforcement.

516.06 Joint Sealers. Before applying joint sealer to the surface, clean the

concrete of foreign matter, curing compounds, oil, grease, dirt, free water, and laitance and clean steel by sand blasting. Apply joint sealer with a minimum depth of 1 inch (25 mm) at its thinnest section. Fill joints to within 1/4 inch (6 mm) of the roadway surface. Separate joint sealer from contact with asphalt concrete using a barrier of foil or other material th at is impervious to the joint sealer. As required to prevent bonding of the joint sealer with a joint surface, place a suitable bond breaker barrier before applying the joint sealer. 516.07 435 Remove joint sealer that did not bond to the joint face as intended withi n 24 hours after placing. Clean the joint by sandblasting and reseal the joint. Mix and place joint sealer according to the manufacturer’s instructions. Provide the Engineer with a copy of the manufacturer’s instructions. Protect joint sealer with an impervious masking tape during the application of concrete protective coatings containing mineral spirits.

516.07 Bearing Devices. For sliding plates, lubricate the sliding surfaces with

flake graphite, and superimpose plates on each other with their edges flush. Install each bridge bearing to within ± 0.125 inch of its marked centerlines in the horizontal plane and oriented to within an angular tolerance of 0.20 rad. (1 degree). Accurately set , level and align elastomeric bearings, bearing plates, and bols ters. Set bearing plates and bolsters on 0.125 inch (3 mm) thick sheet lead, conforming to 711.19. Set bearing plates or bolsters on bridge seat areas that are flat and smoothly finished. If the bridge seat area is high or uneven, use a bushhammer or grinder followed by thin film of portland cement mortar or paste to fill the pitted surface to bring the seat area to the proper elevation and provide a level, even surface. If the bridge seat area is low, use steel plate shims of the same bearing area as the bearing plates and bolsters to bring the seat area to the proper elevation. Set elastomeric bearing pads directly on the concrete surface. If the beams seats are sealed with an epoxy or non -epoxy sealer prior to setting the bearings, do not apply seale r to the concrete surfaces under the proposed bearing locations. If these locations are sealed, or membrane cured, remove the sealer or membrane cure to the satisfaction of the Engineer before setting the bearings. Perform this removal at no expense to the Department . Position rockers, elastomeric bearings, and rollers so that, when the completed bridge is at 60 F (16 C), the rockers and elastomeric bearings are vertical and the rollers are centered on the base. If the steel is erected at an ambient tempe rature higher than 80 °F or lower than 40 ºF and the bearing shear deflection exceeds 1/6 of the bearing height at 60 ºF ± 10 ºF, raise the beams or girders to allow the elastomeric bearings to return to their undeformed shape at 60 ºF ± 10 ºF. Set anchor bolts for bearing devices that are clear of the beam or girder flanges, in the concrete after erecting the main structural steel, except as specified below for bearing devices at abutments. Place reinforcing steel in the bridge seat to not interfere with t he drilling of anchor holes. Accurately set anchor bolts in the holes and embed the anchor bolts in non-shrink, non -metallic grout . Until the anchors’ are installed, prevent water from entering and or freezing in the anchor bolt holes. If structural steel interferes with the setting of the anchor bolts, set the anchor bolts before erecting the steel. The Contractor may determine the location of the bolts by using a template and form holes or embed the bolts when placing concrete or, drilling holes in the ha rdened concrete. Install anchor bolts to project at least 1/4 inch (6mm) beyond the nut when tightened. Damage or burr the threads on the projecting end of the bolt after the nut is tightened. The bolt threads shall not extend to the planes of the contact surfaces 516.08 436 between the connected parts. Include the length of two additional threads to the specified thread length of the bolt to allow for thread runout. Washers no thicker than 1/4 inch (6mm) are permitted under the nut. Permanently fasten bearing devices to the abutments, steel beams, or girders after backfilling the abutments to within 2 feet (0.6 m) of the top of the bridge seat. Where the load plate of an elastomeric bearing is to be connected to the structure by welding, control the welding so that the plate temperature at the elastomer bonded surface does not exceed 300 °F as determined by use of pyrometric sticks or other temperature monitoring devices.

516.08 Method of Measurement. The Department will measure the specified

items by the number of e ach, square feet (square meters), pounds (kilograms), or feet (meters) horizontally along the joint centerline and between the outer limits of the fabricated joint. For deck resurfacing, the Department will measure Structural Steel Expansion Joints extendi ng vertically by the actual horizontal length of joint.

516.09 Basis of Payment. The Department will pay for accepted quantities at

the contract prices as follows: Item Unit Description 516 Foot or Pound Structural Steel Expansion Joints (Meter or Kilogr am) 516 Foot (Meter) Structural Expansion Joints Including Elastomeric ___ Seals 516 Foot (Meter) Elastomeric Compression Seals for Structural Steel Joints, ___ Width 516 Foot (Meter) Folder Copper Strip ___ 516 Foot (Meter) Vertical Extension of Structural Expansion Joints 516 Square Foot ___ Preformed Expansion Joint Filler (Square Meter) 516 Foot (Meter) Joint Sealer 516 Each, Foot, Bearing Devices Square Foot, Pound (Meter, Square Meter, Kilogram) 516 Each, Square Foot ___ inch ( ___ mm) Elastomeric Bearing Pad (Square Meter) 516 Each Elastomeric Bearing with Internal Laminates Only 516 Each ___  ___  ___ Elastomeric Bearing with Internal Laminates and Load Plate ___  ___  ___ 516 Square Foot 1/8-inch (3 mm) Pr eformed Bearing Pads (Square Meter)