814Placement of Concrete Bridge Decks

— PLACEMENT OF CONCRETE BRIDGE DECKS

814.01DESCRIPTION

This work includes the placement of concrete bridge decks by using self -propelled finishing machines.

814.02MATERIALS

Provide materials for all Portland cement concrete mixes that conform to SECTION 601.

814.03CONSTRUCTION METHODS

General. Provide all equipment, tools, and requirements pertaining to the classification, proportioning, and testing for the specified class of concrete, including batching, mixing, handling, placing, curing and finishing, that conform to SECTIONS 601, 808, and 816, as modified in this Section. Contractor’s Plan. Before the start of placing the concrete bridge deck, submit a Shop Drawing to the Engineer for approval for a Placement and Curing Plan specifying the: • Method of concrete conveyance, placement, type, and number of finishing machines • Rate of pour • Estimated time of completion • Screed and rail erection plan* • Sequence of concrete pours • Concrete curing procedure * Ensure that the screed and rail placement are compatible with the deck being finished full width by the finishing machine. Design the support brackets to support the deck finishing machine and screed rails. The Placement and Curing Plan shall be prepared and stamped by a Rhode Island licensed Professional Engineer. Ensure that the Placement and Curing Plan considers weather conditions and that the Plan includes the details and a complete description of equipment to be used in the handling, placement, finishing, and curing the concrete, including the number and type o f personnel who will be engaged in the operation. Approval of this Plan does not relieve the Contractor of the responsibility for the satisfactory performance of the methods and equipment. Base the elevations for setting forms and screed supports on a set of computations but located no more than 10 ft apart. Before placing the concrete, make all necessary arrangements and have all materials on hand for curing and protecting the concrete deck. Do not proceed with concrete placement until the Engineer is satisfied that all necessary steps have been taken to

Part 800 — Bridge Structures August 2025

800-90SECTION 814 — PLACEMENT OF CONCRETE BRIDGE DECKS

ensure compliance with the Contract and that completion of the operation can be accomplished within the required scheduled time. Allow sufficient time to permit inspection by the Engineer. Limitation of Mixing.

requirements meet Subsection 601.03.4 except as modified herein. Do not place the bridge deck concrete when the relative humidity is below 35 percent. When placing concrete, provide suitable equipment and take appropriate actions as approved by the Engineer to limit the evaporation rate of the exposed concrete surface to less than 0.15 lb/sq-ft/hr. Determine the evaporation rate according to Figure 1 below. To maintain the evaporation rate below the specified limit, mist the surface of the concrete with a triple head nozzle immediately behind the finishing machine and until the curing cover is applied. Rate the nozzle at one gallon per minute or less, and ensure that this produces a fine, fog mist that will maintain a sheen of moisture on the concrete surface without ponding.

temperature at time of placement conforms to Subsection 601.03.6.

temperature at the time of placement conforms to Subsection 601.03.5.

damage that may result in surface imperfections of the deck. Ensure thats ufficient polyethylene coverings conforming to Subsection M02.04.2 are available at the site of the work for possible immediate use. Handling. Before concrete placement, ensure that all forms are clean and free of rust, excessive oils, and any foreign debris. The Engineer will inspect all concrete forms and materials such as shear connectors, dams, ductwork, spacers, rebars, and any other required materials before concreting operations commence. Do not weld the forming attachments nor other construction aids to tension flanges. Place concrete continuously without interruption between planned construction or expansion joints.

Part 800 — Bridge Structures August 2025

Figure 1

Part 800 — Bridge Structures August 2025

800-92SECTION 814 — PLACEMENT OF CONCRETE BRIDGE DECKS

Concrete Placement Sequence.

the entire width and for the full length of the bridge. Begin deck placement at the expansion end of the span and terminate at the fixed end. Transverse construction joints are not permitted.

placement sequence specified in the C ontract Plans. The Engineer must approve any deviations. Place all concrete between consecutive joints in a continuous operation. The first pour includes the positive moment area in all spans. The second pour includes the negative moment area and is not placed until a minimum of 72 hours have elapsed from initiation of the first pour. Placement. Except as modified herein, ensure that concrete placement conforms to Subsections 808.03.5 and 808.03.6. Attain a rate of placement so that the concrete is finished before the beginning of initial set. Maintain a minimum rate of placement of 35 cu yd/hr at each finishing machine. Before concrete placement operations begin, shape substantial bulkheads or headers to the required deck surface cross section. If unforeseen circumstances force the concrete placement to cease, install sufficient bulkheads at locations determined by the Engineer and discontinue concrete placement. Remove all concrete beyond the bulkhead. Concrete placement will recommence only with the approval of the Engineer. Place the concrete as a monolithic unit in a continuous operation between joints. Consolidate the concrete by a high frequency internal vibrator that is applied to secure maximum consolidation of the concrete. Ensure that c onsolidation yields concrete free from voids and ensures a dense surface texture, but is not continued so long to cause segregation or bleeding. Maintain a small uniform quantity of concrete ahead of the screed on each pass. Do not allow the quantity of concrete carried ahead of the screed to be so great to cause slipping or lifting. Where the vibratory action of the finishing machine does not provide consolidation according to the rate of placement, have in reserve sufficient vibration equipment to guard against shutdown of the work. Ensure that the reinforcement is not susceptible to damage by the vibrators. Finishing. Use methods, procedures, and equipment that will ensure a uniform riding surface without over- vibration or segregation of the concrete components. Maintain the leading edge of freshly placed concrete approximately parallel to the finishing machine.

striking off, and finishing the concrete deck surface. Provide a finishing machine(s) that has sufficient width to finish the full width of the deck. Ensure that t he weight of the finishing machine(s) does not cause unaccounted for deflection of the bridge members or falsework. Ensure that the machine travels on steel rails, pipe, or other approved grade control, which will be supported by vertical supports securely fastened in place at a maximum spacing of 2 ft to prevent any appreciable deflection between rail supports.

Part 800 — Bridge Structures August 2025

Before placing the concrete, ensure that all screed rails are in place and accurately set to ensure finishing of the concrete deck surface to the required elevations. Provide supports for rails, if embedded in the deck concrete, that can be removed without disturbing the concrete. Do not treat screed rails with form-release compound to facilitate their removal. Extend rails for finishing machines beyond both ends of the scheduled length for concrete placement. Ensure that the extended length is a sufficient distance to allow the finishing machine(s) to clear the concrete to be placed. Provide a finishing machine that can propel itself both forward and backward to enable repeated passes to correct surface irregularities and to produce a surface that conforms to the required profile grade, cross section, and surface smoothness. A maximum of two passes of the machine will be allowed over any given deck area. Operate the finishing machine(s) over the full length of the bridge segment to be finished before beginning concrete operations. Conduct a test run with the screed adjusted to its finishing position. During the test run, check the deflection due to the finishing machine, adjustment of guide rails, and required cover for slab reinforcement. Check the required concrete cover over the top bars by riding the screed over the bars and measuring the cover over the slab reinforcement. Rectify discrepancies that are in excess of the allowed tolerances to secure the required concrete cover. Make all necessary corrections before concreting is begun. Coordinate concrete placement and initial strike- off so that the initial strike- off is never more than 10 ft behind the concrete placement. Make sufficient depth checks behind the machine(s) and along the full length of the span to ensure that the required section and reinforcement cover are provided. On skewed bridge decks, ensure that the placement of the concrete and the operation of the finishing machine is parallel to the skew angle. Correct improper adjustment or operation of the finishing machine that results in inadequate reinforcement cover or smoothness. Unsatisfactory performance, particularly with respect to the surface smoothness attained, may be cause for rejection of the equipment.

surface to allow finishing, straight -edging, making corrections, and setting curing materials. Do not permit workmen to walk in the fresh concrete after it has been screeded. Perform all finishing work, including application of the fog spray and placement of curing mats, from work that bridges support above the deck surface.

erances . Verify that the completed surface of the deck meets the required grades and cross slope both during placement and after the deck has been cured. When the concrete is still plastic, use a 10-ft straightedge to test the deck surface and correct any variance in excess of ⅛ -in. in 10 ft. If this tolerance is not met when tested after the concrete has hardened, correct any variance in excess of ⅛-in. in 10 ft at no additional cost to the Department.

Part 800 — Bridge Structures August 2025

800-94SECTION 814 — PLACEMENT OF CONCRETE BRIDGE DECKS

Curing. In the Placement and Curing Plan, include the following details for curing the concrete.

● Curing method ● Provisions for enclosures, indicating method of holding down enclosure safely in place ● Heat devices, types, and locations around structure ● Method of monitoring temperature of hardened concrete ● Backup systems as required

of a water fog spray and apply continuously until the moist covers are placed on the concrete surface. Continue fog spraying to provide a continuous supply of moisture to maintain a thoroughly moist concrete surface. As soon as concrete finishing operations are completed, promptly cover the newly placed concrete surface with a single layer of clean, heavy duty, water-saturated burlap conforming to Subsection M02.04.1 . Ensure that the burlap is free from cuts, tears, uneven weaving, and contaminants. Place the burlap so that the edges are lapped a minimum of 6 in. Place a 4- mil clear or white polyethylene sheet conforming to Subsection M02.04.2 over the saturated burlap cover. White plastic-coated fiber blankets conforming to Subsection M02.04.2 may be used. Comply with the placement requirements for the burlap edge lapping specification. Do not apply curing compounds in lieu of fog spray and the moist cure process. Ensure that all concrete remains continuously moist and protected against any drying for a minimum period of 14 consecutive days after placement of concrete. Ensure that the burlap covers remain moist for the entire 14-day curing period. Do not allow the concrete to be exposed to an alternating wet and dry condition. If at any time during the curing period the surface of the concrete deck is judged to be losing excessive moisture that adversely affects the curing process, the Engineer may require that the polyethylene sheets be removed and the coverings be saturated. Then recover the saturated coverings with polyethylene sheets. If forms or sections of forms have been loosened and/or removed in advance of the curing period, immediately cover the exposed concrete surface with saturated curing covers and keep the concrete saturated for the remainder of the curing period.

temperature at a minimum of 50°F, and monitor the temperature by a continuously recording thermometer. Continuously maintain the minimum 50°F temperature around the forms and deposited concrete for seven days after concrete placement and above 40°F for the remaining seven days of the curing period. If, during the curing period, the concrete surface temperatures fall below the temperatures outlined in the paragraph above, enclose the structure and provide external heat. Always have the required heating measures ready on short notice during the curing period. If external heat is required, the following applies:

Part 800 — Bridge Structures August 2025

● Do not count the time required for tenting as curing time. ● Maintain external heat on the structure for the first seven days of the curing period. For the next seven days, gradually reduce the external heat so that the uniform change in temperature does not exceed 5°F in one hour nor exceed 50°F (while still maintaining the minimum temperatures stated above) in any 24-hour period. Remove forms as specified in Subsection 808.03.10. If during the curing period the concrete surface temperature falls below 35°F, c oncrete may be rejected if the surface temperature falls below 35°F during the curing period. Take precautions to protect the concrete deck from damage resulting from severe weather conditions during the curing process.

placements. Field cure all Quality Control test cylinders with the concrete deck under identical curing conditions according to AASHTO T23 / R100. Final Finish. Comply with the following for the final finish:

perform the saw cut grooving before the installation of expansion joint systems. ● Equipment. Ensure that the equipment has a positive means of removing the saw cut grooving residue from the deck surface leaving the surface in a clean, near dry condition. ● Surface Preparation – Disposal of Construction Debris . Before initiation of work, submit a debris handling and management plan indicating quantities of residue that are expected to be generated, locations for temporary storage for drying or settling of fines and, if necessary, the location acquired or designated for disposal of residue. ● Disposal. Manage and legally dispose of all debris from the saw cutting operation consistent with applicable health and safety regulations. ● Construction Methods . Ensure that t he entire bridge deck area receives saw cut grooving. Perform saw cut grooving to the deck surface while providing positive lateral drainage by maintaining a constant cross slope between saw cutting extremities in each lane. Apply a saw cut grooved finish to concrete wearing surfaces. Perform this work using a multi-bladed diamond wet saw with circular saw blades. The Engineer may allow the use of a single blade, circular saw tool, where it is determined that this equipment is necessary to complete the work. The Engineer will approve the proposed equipment before the work is initiated.

Part 800 — Bridge Structures August 2025

800-96SECTION 814 — PLACEMENT OF CONCRETE BRIDGE DECKS

Saw cutting may begin only after the specified curing period has elapsed. Cut all grooves in a rectangular shape conforming to the following dimensions: ○ Width: ⅛ in. ±1/32 in. ○ Depth: ¼ in. ±1/16 in. Terminate grooves 4 in. to 12 in. away from curbs, parapets, drainage structures, bridge joints, medians, and exposed edges of the structural concrete slab. During the grooving operations, the Engineer will verify, at random, that the minimum grooved depth is being achieved. If not, then stop grooving operations and make all necessary adjustments, and any repairs, as required by the Engineer. At each location, a minimum of five depth measurements will be taken and the average depth determined. If the average depth is outside the specified depth limits, two additional measurements will be conducted in the vicinity to ascertain non -compliance (i.e., consistently too shallow or too deep). Areas that do not meet the specified minimum groove depth will be subject to corrective action by the Contractor. Areas that exceed the specified maximum groove depth will be subject to a price adjustment of a 1-percent reduction of the concrete cost for that area of diamond grooving performed that day. Supply the Engineer with two accurate, easily readable, gauges with which to verify groove depth. Deliver the gauges and the applicable manufacturer ’s instructions for use no later than seven days before the anticipated start of grooving operations. Do not allow slurry or debris from the grooving operation to accumulate or harden, and prevent the slurry from flowing into drains, onto the roadway slopes, or into water bodies below or adjacent to the bridge. Remove residue continuously and dispose of the slurry or debris properly. Only use rubber-tired vehicles on the bridge deck after saw cut grooving. Saw cut grooves may be either transverse or longitudinal as follows as specified on the Plans: ○ Transverse Saw Cut Grooves. Cut transverse grooves perpendicular to the centerline of the roadway using a single pass. Ensure that the grooves are randomly spaced, ranging from 1¼ in. to 2 in., with 50 percent of the spacings being less than or equal to 1½ in. Submit a spacing pattern to the Engineer for approval. An example of an acceptable random pattern is 1¼, 1½, 1 ⅜, 1¼, 1¾, 1½, 2, 2, 1½, 1¼, 1 ⅜, 2, 1 ⅝, 1¼, 1½, 1½, 1¾, 2, and 1⅝ , with all spaces measured in inches. Do not base spacings solely on multiples of ¼ in., because the result will not be truly random (e.g., do not use a pattern such as 1¼, 1¼, 1¾, 2, 1½, 2, 2, etc.). ○ Longitudinal Saw Cut Grooves. Cut longitudinal grooves parallel to the bridge centerline, or working line, using continuous passes. On curved alignments,

Part 800 — Bridge Structures August 2025

ensure that longitudinal grooves are parallel to the centerline of construction or working line. Ensure that the spacing of longitudinal grooves is 1½ in. Spacing does not need to be variable. Immediately after saw cut grooving, leave the pavement in a washed and clean condition, free of all residue and slurry. Do not permit r esidue to flow across lanes used by the traveling public or into gutters or drainage facilities.

814.04METHOD OF MEASUREMENT

This work will not be measured separately for payment.

814.05BASIS OF PAYMENT

No separate payment will be made for this work. Payment will be included with the payment, and at the Contract unit price per cubic yard for Concrete Superstructure Class HP Bridge Deck. This includes all labor, materials, equipment, and all incidentals required to complete the work, including the mixing, handling, placement, finishing, and curing of the bridge deck concrete. In addition, all costs associated with the management and legal disposal of tipping fees, disposal permits, or applications for permits will be incidental to the concrete work and will not be paid for separately.