643TEMPORARY CONCRETE BARRIER, STRUCTURE MOUNTED

643.1DESCRIPTION—This work is the furnishing, placing, maintaining, and removing of temporary concrete

barrier, structure mounted, as indicated, for maintenance and protection of traffic during construction using bolt through anchors or adhesive anchors, as shown on the Standard Drawings, to attach the barrier to existing hardened concrete structure(s). Temporary concrete barrier applies to bridge construction projects that extend continuously for a maximum of three construction seasons.

643.2MATERIAL—

B7, 105 kips per square inch anchor bolt – 1-inch diameter; hot -dipped galvanized according to the requirements of Class C of ASTM A153. Additional requirements for both ASTM F1554 -99 and ASTM A193/A193M includes ASTM F1554 supplement S5 Grade 105, 105 kips per square inch Charpy Impact Requirements at -20F.

Grade 7, Supplement S3 at -20F; hot-dipped galvanized according to the requirements of Class C of ASTM A153. Provide zinc coating, overtapping of the nut, and lubrication requirements according to ASTM A563.

diameter hole in the middle. All other washers are according to ASTM F436/F436M Type 1. Washers are to be hot-dipped galvanized according to the requirements of Class C of ASTM A153.

approval of a bolt equivalent to an ASTM A193/A193M - 01b Grade B7, 105 kips per square inch anchor bolt – 1-inch diameter; hot dipped galvanized according to the requirements of Class C of ASTM A153. Additional requirement for ASTM A193/A193M includes ASTM F1554 supplement S5 Grade 105, 105 kips per square inch Charpy Impact Requirements at -20F. If using bolts treated for future removal, provide manufacturer recommendations to the Representative and include manufacturer's test data to ensure this operation will not affect the physical properties of the anchor/adhesive combination.

Grade 7, Supplement S3 at -20F; hot-dipped galvanized according to the requirements of Class C of ASTM A153. Provide zinc coating, overtapping of the nut, and lubrication requirements according to ASTM A563.

hole in the middle. All other washers are according to ASTM F436/F436M Type 1. Washers are to be hot- dipped galvanized according to the requirements of Class C of ASTM A153.

specifically for this application. Use material designed for installation type, spacing and minimum temperature considerations. Provide a bonding material that is either a glass/soft -skin capsule or two - component system contained in pre-packed injection (coaxial or side by side) cartridges and that is inserted into the hole using a manufacturer approved dispensing gun and replaceable mixing nozzle.

6.a Performance Requirements. Provide independent test results from the adhesive bolt manufacturer, of the following properties, for review and approval by LTS.

6.b Physical Properties. Determine physical properties in 3 ,000 ±500 pounds per square inch concrete (cured for 28 days minimum) at a maximum depth of 6.5 inches with a 1-inch diameter anchor bolt of equal or greater tensile strength to an ASTM A193/A193M - 01b Grade B7 anchor bolt. Meet the minimum acceptance criterion of one or more of the following categories as shown in the Standard Drawings.

6.b.1 Tension. ASTM E 1512, Procedure - Static Tests, modified for testing at the following temperatures: 32F±1.8F, 73.5F±3.5F, and 125F ±5F, and to meet and be classified as per the tension minimums as shown in the Standard Drawings. Apply test loads to confined specimens to preclude concrete failure but allow bond failure. Concrete specimen size may be modified if necessary.

6.b.2 Shear (Continuous Load Application). ASTM E 488, Shear Test; to meet and be classified as per the shear minimums in.

6.b.3 Shock. ASTM E488, modified for testing as follows:

Number of samples: n=5

Number of shocks of test sample: 3

Shock duration: 0.1 seconds

Conduct the shock test at the following temperatures: 32F±1.8F, 73.5F±3.5F, and 125F±5F, to meet and be classified as per the tension minimums in. Apply test loads to confined specimens to preclude concrete failure but allow bond failure.

6.b.4 Short Term Cure. Perform static tension testing 24 hours after installation as per the procedure for tension testing in ASTM E1512, modified for testing at the following temperatures: 32F±1.8F, 73.5F±3.5F, and 125F±5F, and to meet and be classified as per the tension minimums in. Apply test loads to confined specimens to preclude concrete failure but allow bond failure.

6.b.5 Freeze Thaw. ASTM E1512, to meet and be classified as per the tension minimums in. Apply test loads to confined specimens to preclude concrete failure but allow bond failure.

6.b.6 Damp Hole Installation . ASTM E 1512, to meet and be classified as per the tension minimums in. Before testing b low out the hole with dry compressed air for 1 to 1 1/2 minutes. Apply test loads to confined specimens to preclude concrete failure but allow bond failure.

6.b.7 Test on Effect of Reduced Temperature on Curing. ASTM E1512 modified as follows: Conduct installation/application at the lowest temperature of use specified to meet and be classified as per the tension minimums in. Perform test loads at 75F ±10F before application of the loading and at the specified minimum installation/application temperature. Apply test loads to confined specimens to preclude concrete failure but allow bond failure.

6.c Chemical/Compositional Properties. Provide manufacturer's data indicating th e adhesive system is resistant to gasoline, diesel oil, acids, and caustics. Perform testing according to ASTM D543. The following materials requirements are:

• Concrete Temperature at time of installation:

Minimum 41F* Maximum 109F

* Adhesives designed for installation below 41F may be submitted and evaluated for approval if the lowest temperature of use specified is the installation/application temperature for physical properties testing.

• Installation time at 75F±10F:

Minimum Set time of 0.1 hours Maximum Set time of 6.0 hours Maximum Cure time of 24.0 hours

Provide the following testing information for the tests listed below to the LTS. The information requested will be used to identify, characterize, and classify the material for proper use and to verify composition:

• ASTM D1875 - "Standard Test Method for Density for Adhesives in Fluid Form." Provide production ranges for each component of the system in terms of weight per gallon or specific gravity.

• ASTM D 1252 - "Standard Practice for General Techniques for Qualitative Infrared Analysis ." Provide an infrared analysis of each of the components, and of representative specimen of the cured final product of the adhesive system.

• ASTM D482 - "Ash Filler Content." Provide a value in terms of percent.

• ASTM D570 - "Water Absorption." Provide a value in terms of percent.

• ASTM D1084 - "Viscosity of Adhesives"

• The LTS must approve this information before the product is used.

6.d Storage of Materials. Store materials delivered to the jobsite in the original unopened containers within a facility capable of maintaining storage conditions consistent with the manufacturer's recommendations.

6.e Certification, Shipment to Project, Packaging , and Marking. Certify each shipment as specified in Section 106.03(b)3. Deliver the adhesive bonding material system to the project site in original unopened containers with the manufacturer's label identifying the product. Clearly mark each package with the following information:

• Manufacturer's name and address

• Product name

• Manufacturer Expiration Date

• LOT Identification Number

• Storage and Handling Requirements

Include in each package a copy of the manufacturer's instructions for anchor and installation. Provide instructions that include at least the following information:

• Diameters of drilled holes for applicable anchor and anchor sizes.

• Cleaning procedure for drilled holes, including a description of allowed and prohibited equipment and techniques.

• Allowable temperature ranges for storage, installation, curing, and in-place performance.

• Identification of acceptable mixing/dispensing nozzles.

• Fabrication requirements for anchors.

• Description of tools allowed or required for installation.

• Method of identifying properly proportioned and mixed adhesive materials.

• Time and temperature schedule for initial and set and full-strength cure.

• Special requirements for special installation conditions such as damp holes, or low temperatures, etc.

• Release agents, if used.

643.3CONSTRUCTION—Install top and side delineators as shown on the Standard Drawings . Install

warning lights as directed and according to the manufacturer's recommendations. Maintain alignment, delineation, warning lights, and condition of the barriers as necessary, for the duration of the project. Remove the barriers from the project upon project completion, or when directed. To minimize eradication of paint lines within the work zones, paint continuous white or yellow 6-inch-wide pavement marking on the barrier as shown on the Standard Drawings. Water blast the temporary barrier with a minimum of 3,000 p ounds per square inch before painting and if applicable, remove existing contrasting paint color.

in BC-719M and as directed by the Representative.

anchors is structurally sound and free of cracks in the vicinity of the anchor to be installed. During the initial barrier layout, use a metal detector specifically designed for locating steel in concrete to minimize conflicts with existing steel reinforcement. Move the barrier parallel to the direction of traffic up to 2 inches and perpendicular to traffic up to 1 inch if conflicts with the existing steel reinforcement occur. Maintain a smooth barrier face to traffic along the entire barrier length. Use a rotary drill and bit for drilling the hole for a 1 -inch diameter bolt. Drill into the deck using the holes in the temporary barrier as a template. The drill may be located anywhere within the 2 -inch slot but must be maintained vertically ( ± 1º) and at a 5º cant ± 1º to the vertical from the front face to rear face of the barrier. Drill into the deck using methods that will not shatter/damage the concrete surface adjacent to the holes or result in concrete spalling at the underside of the deck. Notify the Representative if spalling occurs. Patch areas of spalling immediately. If reinforcement is encountered during drilling, before the specified depth is attained, notify the Representative immediately. The hole may be repositioned within the slot in the barrier to avoid damaging the deck reinforcement during drilling; however, the hole must remain vertical. Patch unused or partially drilled holes as specified in Section 643.3(b)7.

Snug tighten heavy hex nuts.

Standard Drawings, as directed by the Representative, according to manufacturer's instructions, and as specified herein.

adhesive anchors.

is structurally sound and free of cracks in the vicinity of the anchor to be installed. During the initial barrier layout, use a metal detector specifically designed for locating steel in concrete to minimize conflicts with existing steel reinforcement whenever placement tolerances and edge clearances allow. Move the barrier parallel to the direction of traffic up to 2 inches and perpendicular to traffic up to 1 inch if conflicts with the existing steel reinforcement occur. Maintain a smooth barrier face to traffic along the entire barrier length. Unless otherwise specified, use the depth of hole and the installation procedure recommended by the manufacturer to conform to BC -719M and the depth of the deck. Provide a copy of the manufacturer's recommended installation procedure, including depth, to the Representative at least 2 days before the start of work. Use rotary drill and bit as recommended by the adhesive manufacturer. Drill holes to the manufacturer's recommendation for a 1 -inch diameter bolt. Drill into the deck using the holes in the temporary barrier as a template. The drill may be located anywhere within the 2 -inch slot but must be maintained vertically (± 1º) and at a 5º cant ± 1º to the vertical from the front face to rear face of the barrier. Drill into the deck using methods that will not shatter/damage the concrete surface adjacent to the holes or penetrate the bottom of the bridge deck resulting in concrete spalling at the underside of the deck. Notify the Representative if spalling occurs. Patch areas of spalling immediately; use a bolt through connection for that hole location. If reinforcement is encountered during drilling, before the specified depth is attained, notify the Representative immediately. The hole may be repositioned within the slot in the barrier to avoid damaging the deck reinforcement during drilling; however, the hole must remain vertical. Patch unused or partially drilled holes as specified in Section 643.3(b)7. Dry the drilled holes completely before cleaning and installing the anchors. Ensure drilled holes are cleaned in acco rding to the manufacturer's instructions and are completely dry at the time of placing the adhesive bonding material and anchors. As a minimum, remove loose particles from drilling, brush inside surface to free loose particles trapped in pores, then remove the remaini ng loose particles to avoid contamination of the adhesive bonding material. Use a non -metallic bristle brush and avoid over -brushing to prevent polishing the inside surface of the drilled hole. Protect holes from contamination and moisture.

by blowing out the drilled hole with dry compressed air. Ensure the drilled holes are cleaned in accor ding to the manufacturer's instructions and are completely dry at the time of placing the adhesive bonding materials and anchors. Install anchors as shown on the Standard Drawings , the structure drawings , and the manufacturer's instructions with particular attention to requirements and limitations because of anchor position, dampness, ambient temperature, and curing. Do not install anchors below 41F or above 109F unless manufacturer data can be provided and LTS has approved and listed the material in Bulletin 15 in advance. Use adequate quantities of the adhesive bonding material to fill the drilled hole to within 1/4 inch of the concrete surface, measured after placement of the anchor. For encapsulated systems, mix materials inside the drilled hole as the capsule and its contents are crushed by the anchor rod, driven by a rotating drill as directed by manufacturer's technical/application data sheets. For pre-packed injection cartridge systems, fill hole completely (without gaps, air bubbles, etc.) from bottom as directed by manufacturer's technical/application data sheets. Insert anchor by hand, turning clockwise to coat threads and remove air bubbles. Support the anchor as necessary to maintain alignment/orientation and prevent movement during curing. Maintain undisturbed until the adhesive has cured the minimum time specified by the manufacturer. Anchors that are improperly bonded, as determined by the Representative, will be rejected. If removal of adhesive anchors is required, perform under the direction of the Representative, and provide manufacturer test data to support that this operation will not damage the surrounding concrete. If possible, drill new anchor holes in both adjacent barrier anchor locations to account for rejected anchors. Otherwise, re-drill holes to remove adhesive bonding material residue and clean as specified in Section 643.3(b)2. Do

not reuse failed anchors. Perform all work necessary to correct improperly bonded anchors at no additional cost to the Department. If adhesive anchors cannot be used, use bolt through anchors as specified in Section 643.3(a).

E488 and ASTM E1512, in the presence of the Representative. In addition, orient the field test load equipment to provide a field load at the same angle and orientation as the anchor being tested . If electing to use another type of field -testing equipment, submit details to the BOPD for review and conceptual approval with field verification by the Contractor. Provide documentation that all field test equipment has been calibrated to the requirements of ASTM E488 and E 4. Perform restrained static tension tests to prevent damage to the surrounding concrete. Test individual anchors to the values shown in BC-719M, Table 2; values in Table 2 are based on 85% of the adhesive anchor tensile capacity. The anchors will be divided into lots for testing and acceptance. Each lot will contain a maximum of 100 anchors of the same embedment length and adhesive bonding material system. 10 percent of the anchors in each lot will be randomly selected for testing, according to PTM No.1, with a minimum of five tests per lot, unless otherwise directed by the Representative. Submit test results to the Representative for each lot. Acceptability of the field tests will be determined according to ASTM E488 and the tension requirements of Table 1. For every failed field test, perform two additional field tests on adjacent untested anchors within the lot. Continue additional field tests until no additional test failures occur, or all anchors within the lot are tested. Remove and replace failed anchors as specified in Section 643.3(b)5. Provisionally approved adhesive anchor systems will be evaluated randomly, for specification compliance, at job completion by secondary field proof load testing immediately before barrier removal.

without damage to the surrounding concrete. If possible, installing new replacement anchors, use adjacent barrier anchor slots as specified in Section 643.3(b)2. Otherwise, re-drill holes to remove adhesive bonding material residue and clean as specified in Section 643.3(b) 2. Reinstall new anchors as specified in Section 643.3(b)3. Do not reuse the failed anchors. Install anchors utilizing a new lot of adhesive bonding material, at the same embedment and field test as specified in Section 643.3(b)4. If adhesive anchors cannot be used, use bolt through anchors as specified in Section 643.3(a).

safety barriers have been removed on the inactive side of the newly placed temporary concrete barrier, do not open the work zone to traffic until all adhesive anchors have been successfully tested. O therwise, the opening of the work zone to traffic will be allowed by the Representative before field-testing of the adhesive bonded anchors. Note cure time will be significantly modified by environmental conditions such as surface temperature, humidity, etc. In these cases, conduct field-testing after the required cure time of the adhesive.

Immediately replace or repair barriers showing the following signs of damage :

• Fractures or cracks, that, in the opinion of the Representative, will hinder the adhesive/barrier performance; or

• Broken or cracked ends where such damage would, in the opinion of the Representative, prevent making a satisfactory joint.

Provisionally approved adhesive anchor systems will be evaluated randomly, for specification compliance, at job completion by secondary field proof load testing immediately before barrier removal. If removal, repair, or replacement of anchors is required, provide the manufacturer's recommendations to the Representative, and include manufacturer's data to support that this operation will not damage the surrounding concrete. After anchor bolt removal (before sealing of anchor bolt holes) clean out the interior of the bolt holes, in such a manner to remove all adhesive/removal materials, that would reduce the performance of the sealing operation. Maintain alignment, delineation, warning lights and condition of the barriers throughout the life of the project. Upon project completion, or when directed, remove the barriers from the project. After barrier removal, treat anchors and anchor bolt holes as shown on the Standard Drawings.

643.4MEASUREMENT AND PAYMENT—

concrete barrier, structure mounted pay item. Labor, materials, tools, equipment, and incidentals; all work involved in drilling holes, bonding anchors and coring through concrete and reinforcement; and removal of barrier and subsequent repair of deck are included in contract unit price. Removal of unacceptable or failed field-tested anchors, as well as all patching/repair of cracked/damaged concrete will be at no additional cost to the Department. Delineation, waterborne markings, water blasting, and removal of contrasting paint are incidental.