BRIDGE DECKS, APPROACHES, RAILS, AND PARAPETS 504.03 327 SECTION 504 BRIDGE DECKS, APPROACHES, RAI LS, AND PARAPETS
504.01 Description
This work consists of constructing concrete bridge decks, approach slabs, and railings and parapets for bridges and other structures.
504.02 Materials
Provide materials in accordance with the following sections and subsections: Material: Section or Subsection: Structural Concrete (Class AA) 509 Reinforcing Steel for Structures 511 Water 701.04 Curing Agents 701.07 Metal Bridge Railing Materials 732.03 Aluminum Alloy Tubes for Railings 732.03 Cast Aluminum Alloy Bridge Railing Posts 732.03 Pipe Railing 732.04 Provide a corrosion -inhibiting admixture for cast -in-place bridge deck concrete and precast deck -form concrete, if using stay -in-place prestressed concrete deck forms.
504.03 Equipment
A.Finishing Machine Provide an Engineer approved, self -propelled finishing machine supported on rails or steel -clad headers capable of transversely finishing the bridge deck and approach slabs. Fasten the rails and headers parallel to the deck centerline and set the line and grade with allowance for dead -load deflections. Before placing concrete, submit a machin e description that includes the make, model, a finishing plan, and an equipment breakdown plan that lists spare equipment and parts and estimates for down time. Spare equipment will include one engine for the finishing machine. Provide enough equipment a nd labor to limit down time so that concrete placement can be completed within the time requirements in Table 509:1 .
B.Fogging Equipment Provide a fogging system that creates fog with pressurized water and a series of foggin g nozzles (not more than 3 ft [1 m] apart) that will continuously cover the finished concrete with cool, moist air. Provide high pressure equipment capable of generating at least 1,200 psi [8.3 MPa] at a flow rate of 2.2 gpm [8.3 L/min], or low -pressure e quipment with nozzles capable of supplying a maximum flow rate of 1.6 gpm [6.1 L/min]. Mount fogging equipment to the trailing edge of strikeoff, work bridges, or both with nozzles positioned to spray above a horizontal plane. Provide hand held foggers f or areas
504.04 Bridge Decks, Approaches, Rails, and Parapets
328 which require supplemental fogging. Do not use hand held foggers as the primary fogging equipment or as a finishing aid.
C.Grooving Machine Provide a self -propelled grooving machine to groove hardened concrete if saw -cut grooving is required by the Contract. Use a grooving machine equipped with the following features: Diamond saw blades mounted on a multi -blade arbor at the Contract required spacing, A depth control device that detects variations in the concrete surface and adjusts the height of the cutting head to maintain the Contract required depth, An alignment control device, and A vacuum attachment that removes and collects slurry or residue from the grooving operation.
D.Work Bridges Provide at least two work bridges to provide access for floating, straight edging, fogging, curing, and finishing the concrete.
504.04 Construction Methods
Ensure the bridge deck thickness is ±½ in [±12 mm] from the thickness dimensions shown on the Plans. The Engineer may direct removal and replacement of spans or sections between construction joints if the thickness tolerance is not met. Where deck is continuous over abutments or piers, place construction joints in acc ordance with subsection 518.04A, "Construction Joi nts." Place joints at the ends of simple spans unless otherwise shown in the Contract documents. Wait at least 24 hours before placing adjacent span at fixed construction joints. Construct approach slabs in accordance with Sect ion 414, “Portland Cement Concrete Pavement,” except as modified by Section 504.
A.Forming, Bracing, and Finishing Machine Rails At the pre -work meeting, submit to the Engineer for approval, a Bridge Deck Plan that covers the following: Falsework, forming, and bracing details in accordance with Subsection 502.04.A, “Falsework,” Stay -in-place form shop drawings, lap details, and methods for sealing corrugations, and method of attachment to be ams in accordance with Subsection 502.04.B, “Forms. ” Placing, consolidating, finishing, fogging, and curing equipment and back -up equipment located on-site in accordance with Subse ction 504.03, “Equipment.” Quantities of material and numbers of equipment for rainy, cold, and hot weather protection in accordance with Subsection 509.04.B, “Protection of Concrete from Environmental Conditions.” Concrete mix design, the plant supplying the concrete, and the expected delivery and placement time in accordance with Subsection 701.01, “Mix Design and Proportioning,” and Subsecti on 509.04.C, “Handling and Placing Concrete.” Quality control plan for concrete placement that includes the purpose, intent, and interpretation of the QC specifications. BRIDGE DECKS, APPROACH ES, RAILS, AND PARAPETS 504.04 329 Identification of checks used to ensure the deck conforms to the dimensions shown on t he Plans and quality required by the Contract. Process for delivering, placing, consolidating, finishing, and curing the concrete in accordance with Section 504 “Bridge Decks, Approaches, Rails and Parapets ” and Section 509, “Structural Concrete.” Begin falsework after the Engineer approves the Bridge Deck Plan. Provide forms and bracing for the deck overhang to support the weight of construction loads. Brace exterior steel girders to prevent girder rot ation and over stressing the girder web in accordance with Subsection 502.04.A(6), “Falsework for Steel and Precast Concrete Beams and Girders.” Set rails on non -yielding supports outside the concrete placement for the length of the deck to allow the finishing machine float to clear the concrete. Use rails that adjust for elevation. Set rails to allow for settlement, camber, and deflection of falsework. Adjust rails to correct for additional settlement or deflecti on during finishing operations. If located within the deck, remove the rail supports to at least 3 in [75 mm] below the finished surface when the concrete placement operation no longer requires them. Fill the void with fresh concrete.
B.Construction Joi nts and Expansion Devices Build construction joints and expansion devices in accordance with Section 518, “Construction Joints and Expansion Devices .”
C.Reinforcing Steel Placement Place reinforcing steel in accordance with Section 511, “Reinforcing Steel for Structures. ” Place transverse reinforcing steel bar ends 2 in [50 mm] from the edge of the deck or slab. Place the ends of longitudinal reinforcing steel bars and parapet bars 1 in [25 mm] from the end of the concrete or expansion device. Ensure tolerances in accordance with Subsection 511.04.B, “Placing and Fastening.” Support reinforcing steel with wire supports. Unless otherwise required by the Contra ct, extend longitudinal reinforcing steel bars through construction joints.
D.Concrete Place concrete in accordance with Section 509, “Structural Concrete.”
1.Pre -Deck Pour Inspection At least 24 hr before placing the deck an d with the Engineer present, inspect for the following: Forms are mortar tight, cleaned, and oiled. Stay -in-place steel forms are lapped in the direction required by the Contract. Concrete panels are set to allow concrete to flow between the bottom of the panel and the top of the beam in accordance with Section 502, “Forms, Falsework, and Temporary Works.” Falsework has been inspected and certified, and tell -tales installed and marked in accordance with Section 502, “Forms, Falsework, and Temporary Works.”
504.04 Bridge Decks, Approaches, Rails, and Parapets
330 Reinforcement is clean, coating damage is repaired, ties are tight, support provides a stable mat, and clearances and spacing meet plan dimensions and tolerances in accordance with Section 511, “Reinforcing Steel for Structures.” Finishing machine rails are stable. Back -up equipment is on site. No oil or fuel leaks from machinery. The dry run produces cover, clearance, and deck thicknesses in accordance with Table 502:1, "Maximum Dimensional Tolerances for Cast in Place Formed Concrete." Equipment and materials for weather protection are in place. Temperature reading locations during cure period are identified in accordance with Section 509, “Structural Concrete.” Work bridges, curing materials, and equipment are prepared for concrete placement. Fogging application equipment is in good working order with no leaks. Sufficient quantities, personnel and methods for placement of curing mats, including procedures for pre -wetting and maintaining moisture in curing mats during cure time. Identify locations for concrete discharge, sampling, and testing in accordance with Subsection 701.01, “Mix Design and Proportioning.” Begin placing the deck with the Engineer’s approval.
2.Placement Deposit the concrete ahead of the finishing machine and slightly higher than the finished surface. Always maintain excess concrete in front of the screed cutting edge. Carry the excess to the edge of the pour or forms, and remove. Place concrete at a rate of at least 25 ft/hr [8 m/hr] measured longitudinally along the bridge deck. Refer to Subsection 509.04.B, “Protection of Concrete from Environmental Conditions” for concrete construction practices appropriate to weather conditions at time of construction.
3.Lighting Place concrete at night in accordance with Subsection 509.04.C (3)(c), “Lighting.”
4.Finishing After consolidating the concrete, use the finishing machine to transversely strike -off the concrete to the profile shown on the Plans. Use a float to finish the concrete to a smooth, even surface along the bridge length. Finish transversely, unless the Contract allows longitudinal finishing. Do not spray water on the concrete surface to assist finishing operations. Test the surface line and grade with a 10 ft [3 m] straightedge while the concrete is plastic. Fill depress ions with fresh concrete and remove high areas. Consolidate, strike -off, and refinish the repaired areas. Ensure the surface across joints is in accordance with Subsection 401.04.A(1), "Surface Elevation and Smoot hness." BRIDGE DECKS, APPROACHES, RAILS, AND PARAPETS 504.04 331 Finish approach slabs the same as bridge decks. For overlaid approach slabs, use the same final finish as for bridge deck overlays.
5.Fogging and Curing Requirements Fog all bridge deck placements. Begin fogging bridge decks behind the finishi ng operations for the entire deck width. Continue fogging to produce a semi -gloss water sheen on the surface until application of the curing material. Reduce fogging if water accumulates on the surface and begins to run off. Ensure the fogging nozzles a tomize the droplets and dampen without creating pools of water. Do not use water from fogging as an aid to finish the concrete. Continuously cure the concrete immediately after finishing for at least seven days. If using a pozzolan, such as flyash, of gr eater than 10 percent, continuously cure the concrete immediately after finishing for at least seven days for Type C flyash and 10 days for all other pozzolans including Type F flyash. Cure the bridge deck or approach slab in accordance with Subsection 504.04. D(5)(a), “Water with Waterproof Cover.” Cure pedestrian walkways the same as bridge decks. The Department will not allow the use of curing compounds during the seven day curing period.
a.Water with Waterproof Cover Continuously apply fog after the concrete strike -off and until covering the concrete with wet burlap. Mount fogging equipment on the finishing equipment. Prevent the water from dripping, flowing, or ponding during fogging, placement of a bsorbent material, or before the concrete sets. Apply one layer of wet burlap, or an alternative material approved by the Engineer, within 30 min of concrete strike -off. Apply a second layer within 5 min. Maintain a moist surface after strike -off and dur ing the curing period. Using a misting hose, keep the burlap saturated until the concrete sets enough to allow foot traffic. When the concrete sets, place soaker hoses on the burlap and supply water to maintain continuous saturation of the burlap over the entire concrete surface. Place white polyethylene film over the soaker hoses covering the concrete surface. Use the widest available sheets and overlap adjacent sheets at least 6 in [150 mm]. Use a pressure sensitive tape, mastic, glue, or other Enginee r approved adhesive to tightly seal and form a waterproof cover. Secure the polyethylene film to prevent displacement by the wind. Repair or replace sheet portions that become damaged before the end of the curing period, or lose waterproofing ability.
b.Curing Membrane Provide curing compounds in acc ordance with subsection 701.07C, "Liquid Membrane Curing Compounds." Ensure curing compound has not expired. Within 30 minutes of removing wet burlap and polyethylene, apply two coats of curing membrane while the surface is damp. Apply the curing membrane at a coverage rate of at least 1 gal per 160 ft² [1 L per 4 m²] unless otherwise required by the Contract. If the concrete surface dries, fog spray to maintain a dam p condition. Spray the second coat of curing membrane immediately after and perpendicular to the first.
504.04 Bridge Decks, Approaches, Rails, and Parapets
332 Protect the curing membrane for at least seven days. Apply an additional coat to marred areas of the membrane. If the curing membrane is continuously marred, the Engineer may direct the application of wet burlap, polyethylene sheeting, or other impermeable material to ensure Contract required concrete curing.
6.Removing Forms Remove forms in accordance with Subs ection 502.04.C, “Removal of Forms and Falsework.”
E.Surface Correction through Grinding Test the concrete driving surfaces using a 10 ft [3 m] straightedge or other Contract allowed device after curing. Mark and grind areas with spots higher than ⅛ in [3 mm]. Begin grinding after completion of the curing period, and in accordance with Section 425, “Diamond Grinding Concrete Pavement.” Grind areas that do not meet smoothness specifications in accordance with Subsection 401.04.A(1), "Surface Elevation and Smoothness." Do not reduce the concrete cover over reinforcing steel to less than 2 in [50 mm]. Restore the skid -resistant surface in ground areas using saw-cut grooving. Remove and r eplace, at no additional cost to the Department, bridge decks and approach slabs that cannot be corrected to meet the specified tolerances. The Department will not measure grinding for surface correction for payment.
F.Longitudinal and Transverse Groovin g
1.Groove Geometry Saw-cut grooves to the dimensions and tolerances specified in Table 504:1. Table 504:1 Dimension and Allowable Size of Saw -Cut Groove Dimension Transverse Allowable Size, in [mm] Longitudinal Allowable Size, in [mm] Width 1/8– 1/4 [3 – 6] 1/ 8+/ – 1/64 [3mm +/ - 0.4mm] Depth 1/8 – 3/16 [3 – 5] 1/8 + 1/32 -1/16 [3mm + 0.8mm/ - 1.6mm] Spacing a (c/c) ½ – 1 [12 –24]a 3/4 [19mm] center to center groove a Randomly vary the groove spacing from ¾ in to 1½ in [19 mm to 38 mm] on bridges at least 1,000 ft [300 m] long. Make the groove cross -sections rectangular for saw -cut grooves. Measure the width tolerance at the mid -depth of the grooves. Cut grooves within 2 ft [0.6 m] of the parapet face, guardrail, or curb. Continuously run the gr ooves across the width of the bridge to within 2 ft [0.6 m] of the opposite parapet face, guardrail, or curb. The Department will not allow cutting of grooves within 6 in [150 mm] of a construction joint, with the exception of skewed joints . Terminate lo ngitudinal grooving 6 in +/ - ¼” [150mm +/ - 6mm] from expansion joints. Do not overlap parallel grooving patterns. For curved bridges, cut grooves transverse to the curve cord within the spans. BRIDGE DECKS, APPROACHES, RAILS, AND PARAPETS 504.04 333 (2) Grooving Hardened Concrete Provide saw -cut longitudinal and transverse grooves under the following conditions: The Department specifies saw -cut longitudinal and/or transverse grooving as a pay item, Replace longitudinal and transverse grooving after grinding, and Correct out -of-tolerance longitudin al or transverse grooving . Begin saw -cut grooving after completion of the concrete curing period and grinding repairs. If spalling occurs, discontinue grooving and correct the cause. During grooving work, if a single blade on a multi -blade grooving machi ne can no longer cut a groove, repair the damaged blade after completion of the shift. The Engineer will not require the repair of the omitted groove. If more than one blade is damaged, discontinue use and repair the damaged areas as directed by the Engi neer.
3.Slurry Removal While grooving, continuously vacuum the slurry and residue. Prevent the flow of slurry into open traffic lanes or drainage facilities. After grooving, clean slurry residue from the pavement or bridge deck. Dispose of slurry off the project site at an approved waste site as per Subsection 104.09, “Removal and Disposal of Salvaged Materials Structures and Obstructions,” and Subsection 107.01, “Laws, Rules, an d Regulations to be Observed, ” as required by the Contract.
G.Load on Decks and Approach Slabs Apply loads to bridge decks and approach slabs in accordance with Section 509.04 .I “Application of Loads Including Bridge Decks and Approach Slabs .” Permit foot traffic during the seven day curing period. After the deck has cured sufficiently to not be damaged by operations, permit the placement of reinforcing steel and forms for the bridge rail or barrier. Obtain the Engine er’s approval before operating a mixer on the bridge deck or approach slab. The Department will only allow rubber tired construction vehicles on bridge decks or approach slabs unless approved by the Engineer.
H.Rails, Parapets, and Curbs Construct concre te rails, parapets, and curbs in accordance with Section 509, “Structural Concrete,” and Section 511, “Reinforcing Steel for Structures. ” Do not place railings, parapets, and curbs until the span falsework is released and the dead load deflections have occurred for cast -in-place slab span, box girder, or post -tensioned superstructures.
1.Forming Provide forms in accordance with Section 502, “Forms, Falsework and Tempora ry Works. ” The Department will allow the slip form method of parapet construction if the results and curing, finishing, and protection of the concrete comply with the Contract.
2.Curing Cure rail and parapet concrete in accordance with Subsection 509.04.F(2), “Forms -in-Place Method,” or Subsection 509.04.F(3), “Water Method.” Use either the forms -in-place or the water curing method. Use the water method on exposed surface s. If removing forms and applying finish before the end of the specified curing period, resume curing for the remainder of the curing period.
504.06 Bridge Decks, Approaches, Rails, and Parapets
334 (3) Finish Provide a Class 2 finish for rail and parapet concrete surfaces, and curb sides in accordance with Subsection 509.04.G(2), “Class 2, Rubbed Finish.” Use a wooden float to finish the tops of curbs.
4.Line and Grade Build the line and grade of the parapet or rail as required by the Contract. Unless otherwise requi red by the Contract, make parapets vertical. Construct handrails parallel to curbs.
504.05 Method of Measuremen T
The Engineer will measure the following: Area of Approach Slabs by the top surface dimensions required by the Contract or approved by the Eng ineer. Area of Saw-Cut Grooving bounded by the ends of the approach slabs and the edges of the clear roadway. Concrete Rail, Concrete Parapet, or Handrailing with concrete posts from the outside of the end posts with no deduction for expansion joint gaps. Handrailings with metal posts from end to end. The Engineer will not measure grinding for surface correction.
504.06 Basis of Payment
The Department will pay for each pay item at the contract unit price per the specified pay unit as follows: Pay Item: Pay Unit:
A.APPROACH SLAB Square Yard [Square Meter]
B.SAW -CUT GROOVING Square Yard [Square Meter]
D.CONCRETE RAIL Linear Foot [Meter]
E.CONCRETE PARAPET Linear Foot [Meter]
F.HANDRAILING Linear Foot [Meter] The Department will pay for the quantities of Class AA concrete and reinforcing steel for concrete bridge decks shown on the Plans in accordance with Section 509, “Structural Concrete,” and Section 511, “Reinforcing Steel for Structures.” The Department will consider the cost of lighting to be included in the contract unit price for the relevant pay item. Unless otherwise required by the Contract, the Department will pay for incidental steel items (metal drains) in accordance with Section 506, “Structural Steel,” and Section 511, “Reinforcing Steel for Structures.” OVERLAY OF CONCRETE BRIDGE DECKS 505.03 335 SECTION 505 OVERLAY OF CONCRETE BRIDGE DECKS
505.01 Description
This work consists of preparing deck surfaces and placing a concrete, multilayer polymer concrete, or asphalt membrane overlay on a bridge deck and the approach pavement to provide a smooth transition to the main line pavement.
505.02 Materials
Provide materials in accordance with the following section and subsections: Material: Section or Subsection: Portland Cement Concrete 701.01 High Density Concrete for Bridge Deck Repair and Overlay 701.1 Latex Modified Concrete for Bridge Deck Overlays 701.11 Early Strength Concrete for Bridge Deck Patching and Overlays 701.2 Type N - Epoxy -Urethane Copolymer Overlay System 701.13.B.(13) Waterproof Membrane for Asphalt Overlay 712.09 Reinforcing Steel for Structures 511 Provide the following overlay types as required by the Contract: High density concrete (HDC), Latex modified concrete (LMC), Early Strength concrete (ESC), or Other materials as required by the Contract.
505.03 Equipment
Provi de equipment with traps, filters, drip -pans, or other devices to keep oil and deleterious material off the deck. Use the following types of surface preparation equipment as required by the Contract:
A.Hydrodemolition Equipment Provide hydrodemolition equipment with a filtering and pumping unit that operates with self-propelled, computerized equipment. Ensure the hydrodemolition equipment uses a high pressure water jet that can remove unsound concrete in a single pass. Provide equipment capable of pro ducing a minimum pressure of at least 13,000 psi [90 Mpa] and selectively removing all deteriorated and unsound concrete in one pass.
B.Mechanical Scarifying Equipment Use self -propelled equipment to maintain accurate depth of cut and slope. Use equipmen t that automatically establishes profile grades along both edges of the machine by referencing the bridge
Source: Oklahoma Standard Specifications for Highway Construction, 2019 Edition. Pages 341–348 of 935.