1080PRESTRESSED CONCRETE BRIDGE SUPERSTRUCTURE

1080.1DESCRIPTION—This work is the construction of a prestressed concrete bridge superstructure.

1080.2MATERIAL—

• Cement Concrete Structures. Section 1001.2

• Preformed Neoprene Compression Joint Seal for Bridges. Section 1008.2

• Pedestrian Railing. Section 1012.2

• Aluminum Bridge Hand Railing. Section 1023.2

• Steel Bridge Hand Railing. Section 1022.2

• Protective Barrier. Section 1015.2

• Protective Fence. Section 1016.2

• Penetrating Sealers for Reinforced Concrete Surfaces. Section 1019.2(a)

• Armored Preformed Neoprene Compression Dam. Section 1021.2

• Tooth Expansion Dam with Drain Trough. Section 1020.2

• Reinforcement Bars. Section 709.1

• Neoprene Strip Seal Dam. Section 1026.2

• Prestressed Concrete Bridge Beams. Section 1107.02

• Plain Steel Bars. Section 709.1(a)2

• Closed Cell Neoprene Sponge. Sections 1107.02(p)1 and 1107.03(e)3

• Plain and Laminated Neoprene Bearing Pads. Sections 1113.02 and 1113.03(g)

• Bedding Material for Bridge Shoes. Section 1113.03(h)

• Steel Bearings. Section 1107.02(j)

• Post Tensioning, when required. Section 1108.02

• Nonshrink Epoxy Grout for Shear Keys. Section 1080.2(g)

• Nonshrink Grout for Studs, Dowels, and Anchor Bolts. Section 1001.2(e)

• Epoxy Resin Aesthetic or Protective Coating. Section 1044 or 1045, as indicated

• High Load Multi-Rotational Bearings. Section 1111

and certified as specified in Section 106.03(b)3, or mix as follows:

• One part Non-shrink Grout Admixture. Bulletin 15. Certify as specified in Section 106.03(b)3.

• Two parts Cement, Type IP, IS or II. Section 701

• Three parts Fine Aggregate, Type A. Section 703.1

• Water. Section 720.1

Required minimum compressive strength:

• 1,000 pounds per square inch at 24 hours

• 4,000 pounds per square inch at 28 days

Combine dry materials in the mixer, then agitate to mix. Add water slowly and mix for 3 minutes or less, or according to the manufacturer's instructions. Mix as closely as possible to the site of the work and use each batch within 20 minutes. Do not retemper. Mold daily test cylinders according to PTM No. 521. Test cylinders according to PTM No. 604.

to the Inspector -in-Charge a complete list of the names and addresses of firms that are to fabricate or supply incidental, fabricated structural steel items to be used in conjunction w ith, or as a part of, the prestressed concrete members.

Section – Polymer Modified and Special Cements, Mortars, and Concrete in Bulletin 15 conforming to the following specifications:

• Polymer modified

• Non-shrink

• Non-sag consistency

• Application thickness range. 1/8 inch to 1/2 inch

• Properties Initial set time (AASHTO T 131) 1/2 hour minimum Compressive strength (AASHTO T 106)

2,500 pounds per square inch—24 hours 3,500 pounds per square inch—7 days 5,000 pounds per square inch—28 days

Slant shear bond test (ASTM C882, Modified) 2,000 pounds per square inch—7 days

Freeze-thaw resistance (PTM No. 633) 8%—maximum loss by weight

Certify as specified in Section 106.03(b)3.

Use Nonshrink Epoxy Grout as specified below:

Required minimum compressive strength:

• 4,000 pounds per square inch at 24 hours

• 5,000 pounds per square inch at 28 days

1080.3CONSTRUCTION—

and includes bearings, bearings and anchors set in the substructure, abutment backwalls, cheekwalls, shear blocks, bridge drainage down to, but not including, the drain box, and portions of wings and appurtenances above the horizontal construction joint nearest the bridge seat. At the bridge site, beams will be inspected for possible damage, cracking, and twisting during shipment, and for camber, tolerances, and dimensions. Replace beams damaged by improper storing, handling, transporting, or erecting at no additional cost to the Department.

and as follows:

• Fabricated Structural Steel. Section 1105

• Cement Concrete Structures. Section 1001.3

• Preformed Neoprene Compression Joint Seal for Bridges. Section 1008.3

• Pedestrian Railing. Section 1012.3

• Aluminum Bridge Hand Railing. Section 1023.3

• Steel Bridge Hand Railing. Section 1022.3

• Protective Barrier. Section 1015.3

• Protective Fence. Section 1016.3

• Tooth Expansion Dam with Drain Trough. Section 1020.3

• Reinforcement Bars. Section 1002.3

• Neoprene Strip Seal Dam. Section 1026.3

• Armored Preformed Neoprene Compression Dam. Section 1021.3

• High Load Multi-Rotational Bearings. Section 1050.3(c)4.h

Engineer registered in the State. Provide details for all anticipated phases and conditions during erection.

Include details of falsework, temporary bents, bracing, guys, dead-men, lifting devices, and attachments to bridge members. Include the sequence of erection, location of cranes and barges, crane capacities, crane operator’s license for the operator performing the crane work, location of lifting points on the bridge members, and weights of the members. If required, furnish calculations to demonstrate that allowable stresses are not exceeded, and that member capacities and final geometry will be correct. Include delivery plan with erection plan. The delivery plan is to include delivery routes, ingress and egress to the site, and any modifications required for safe transport to the site. List equipment needed to unload or move bridge members. Do not proceed wit h erection until the erection plan has been accepted. Maintain an accepted copy of the erection plan onsite during erection operations.

1.a Pre-Erection Meeting. Before erecting falsework or permanent bridge members, conduct a pre-erection meeting a minimum of 14 calendar days before erection with the Professional Engineer of record for the erection plan, prime contractor, superintendent in charge of beam setting o peration, crane operators or crane company representative, signal personnel, Structure Control Engineer, and onsite Representative to discuss the accepted erection plan. Conduct safety talk with crane operator as specified in Section 108.05(c)6.

1.b Conformance to Erection Plan. Ensure conformance to the erection plan. Any modification to or deviations from the accepted erection plan will require revised drawings, calculations, and verification of stresses and geometry.

1.c Erection Stresses. Account for any erection stresses that are induced in the structure as a result of the use of a method of erection or equipment which differs from that indicated or specified, and which will remain in the finished structure as locked-in stresses. Provide additional material, at no additional cost to the Department, to keep both temporary and final stresses within the allowable limits used in design. Provide temporary bracing or stiffening devices to accommodate handling stresses in individual members or segments of the structure during erection. Use wind loads and distribution of wind loads to girders according to AASHTO Guide Specifications for Wind Loads on Bridges During Construction.

1.d Maintaining Alignment and Camber. During erection, support segments of the structure in a manner that will produce the proper alignment and camber in the completed structure. Install cross frames and diagonal bracing, as necessary during the erection process, to provide stability and ensure correct geometry. Provide temporary bracing, if necessary, at any stage of erection.

waterproofing and other material as required to expose all sides of the pad. If a gap between the pad and bearing surfaces is present, proceed as follows unless the contract plans indicate that a lift -off condition is expected when the beam is initially set on the pad:

• Gap Thickness > 3/8 inch. If a gap along any edge of the pad exceeds 3/8 inch, grind the bearing surface of the substructure to eliminate the gap, except gaps along the front edge of the pad (edge toward the midspan of the beam) will be allowed as specified in Steps 1 and 2 below. Provide a rough textured bearing surface after grinding. Verify that the minimum required vertical clearance to the bottom of beams, as indicated, is maintained after grinding.

• Gap Thickness ≤ 3/8 inch. If gaps along any edge of the pad are less than or equal to 3/8 inch, proceed as follows:

Gap Along Rear Edge of Pad Only . If a gap occurs anywhere along the rear edge of the pad (edge toward the end of the beam), eliminate the gap by placing a leveling bed of polymer-modified mortar beneath the pad as specified in Section 1080.3(c)2.a.

Gap Along Side Edges of Pad . If a gap occurs along the side edges of the pad, and there is full contact at the front and rear edges, eliminate the gap by placing a leveling bed of polymer-modified mortar beneath the pad as specified in Section 1080.3(c)2.a.

Gap Along Front Edge of Pad. If a gap occurs along the front edge (edge toward the midspan of

the beam of the bearing pad), proceed as follows:

Step 1: Determine the area of non -contact between the pad and beam. If the amount of non - contact is less than 20% of the pad area, proceed to Step 2; otherwise eliminate gap by grinding of bearing surface. A leveling bed of polymer -modified mortar beneath the pad as specified in Section 1080.3(c)2.a may be used instead if approved by the Structural Control Engineer.

Step 2: Measure the maximum gap thickness along the front edge and proceed as follows:

Spans < 100 feet Gap Thickness ≤ 3/32 inch: Leave gap in place. 3/32 inch < Gap Thickness ≤ 3/8 inch: Eliminate the gap by placing a leveling bed of polymer-modified mortar beneath the pad as specified in Section 1080.3(c)2.a.

Spans ≥ 100 feet Gap Thickness ≤ 1/8 inch: Leave gap in place. 1/8 inch < Gap Thickness ≤ 3/8 inch: Eliminate the gap by placing a leveling bed of polymer-modified mortar beneath the pad as specified in Section 1080.3(c)2.a.

2.a Leveling Bed of Polymer-Modified Mortar, Placement Procedure.

recommendations. Do not extend mortar by adding coarse aggregate.

perimeter of the bearing pad. Apply the mortar in a thickness approximately 1/8 inch greater than the maximum actual gap thickness.

sponge material around bearing area.

Place mortar according to temperature restrictions recommended by the manufacturer. Do not place a leveling bed of mortar before the initial setting of beams.

.

for horizontal alignment plus 1/2 inch, as specified in Section 1107.03(e)1.b.

where shear keys are present to provide a rough and bondable surface and to remove oil, grease, dirt, or material that would prevent bonding. Just before erection, clean the roughened surface with oil free compressed air, clean stiff -bristle fiber brushes, or vacuum. Seal joints at the bottom of beams below the shear keys with caulking, suitable backer rod , and/ or closed cell neoprene sponge as sho wn on the Standard Drawings.

specified in Sections 910.2(b) and 1080.2(g) . Place grout quickly and continuously into the joints. Follow the manufacturer's recommendations for filling in hot or cold weather.

Do not allow construction activity or other loadings on the bridge for at least 24 hours after the grout has been placed. For vehicular loading, Section 1080.3(d)5 applies.

saturated burlap. Keep the burlap wet during the curing period for at least 24 hours. During cold weather, prevent freezing of the grout. Provide curing temperatures of 50F or above.

compressive strength is 3,200 pounds per square inch minimum.

aesthetic or protective coating, as specified in Section 1044 or 1045 .2(c), respectively . Apply coating as specified in Section 1044.3 or 1045.3, respectively. Cure the coating according to the manufacturer’s recommendations.

then erect the beams. Use a wire brush and clean vertical end notches in beams of adjacent box beam bridges, then seal by caulking with a suitable backer rod. Wet the backer rod 1 hour before grouting. Fill the notches with nonshrink grout. Cure with wet burlap for at least 24 hours.

1050.3(c)4.c.2.

specified in Section 1108.03.

1080.4MEASUREMENT AND PAYMENT—Lump Sum. The price includes the following component items.

• Prestressed Concrete Bridge Beams. Linear Foot

• Preformed Neoprene Compression Joint Seal for Bridges. Section 1008.4

• Pedestrian Railing. Section 1012.4

• Aluminum Bridge Hand Railing. Section 1023.4

• Steel Bridge Hand Railing. Section 1022.4

• Protective Barrier. Section 1015.4

• Protective Fence. Section 1016.4

• Aesthetic Coating for Concrete Surfaces. Section 1044.4

• Penetrating Sealers for Reinforced Concrete Surfaces. Section 1019.4

• Protective Coatings for Concrete Surfaces. Section 1045.4

• Tooth Expansion Dam with Drain Trough. Section 1020.4

• Armored Preformed Neoprene Compression Dam. Section 1021.4

• Reinforcement Bars. Section 1002.4

• Neoprene Strip Seal Dam. Section 1026.4

• Cement Concrete Structures. Section 1001.4

• Fabricated Structural Steel. Section 1050.4

• High Load Multi-Rotational Bearings. Section 1050.4

• Reset Expansion Bearings, Prestressed Concrete Superstructure. Each