SECTION 816 — CONCRETE BRIDGE DECK OVERLAYS — CONCRETE BRIDGE DECK OVERLAYS
816.01 Description.
This work includes placing a Portland cement concrete overlay on a prepared surface of bridge decks, precast concrete butted box beams, deck slabs, deck planks, or other specified concrete substrate at the required locations.
816.02 Materials.
Use Portland cement concrete that is Class HP and conforms to SECTION 601 , except as modified herein.
816.03 Construction Methods.
Existing Bridge Decks.
a.Surface Scarification. Scarify existing bridge decks in an approved manner.
b.Surface Preparation. Perform the blast-cleaning of an area of the deck before the 24-hour water soak period preceding placement of the overlay on the area . Perform t he blast- cleaning by a method approved by the Engineer in writing. Clean all debris, including dirty water, resulting from the blast -cleaning operations from the blast -cleaned surfaces and from other areas where debris may have accumulated. Remove all dust and other debris. Protect the blast-cleaned areas, as necessary, against contamination before the 24-hour presoaking. Blast-clean contaminated areas and areas exposed more than 36 hours after cleaning again, as directed by the Engineer and at no additional expense to the Department. Soak the prepared surface with clean water for not less than 24 hours before the placement of the Class HP concrete overlay. Maintain the surface in a clean, saturated condition by using polyethylene film or other suitable water -impermeable clear covers, until ready to receive the overlay. Before the overlay is applied, blow off all standing water with oil-free compressed air. Precast Concrete Butted Box Beams, Deck Slabs, or Deck Beams. Finish the surfaces of Precast Concrete Butted Box Beams, Deck Slabs, or Deck Planks upon which an overlay will be applied with a roughened surface with amplitude of ¼ in. minimum. Ensure that the method of roughening does not cause cracking. After the placement and curing of the shear key grout and successful post -tensioning of the structural elements is complete, and before placing the overlay, blast-clean the entire area of the deck according to Subsection 816.03.1(b). Ensure that the profile is maintained after blast cleaning. Protect galvanized reinforcing steel and any other appurtenances cast into the surface of the precast elements from the effect of the blast medium so that damage to the galvanization does not occur.
Part 800 — Bridge Structures August 2025
SECTION 816 — CONCRETE BRIDGE DECK OVERLAYS 800-103 Bonding Grout. Apply bonding grout as follows. After the surface has been cleaned and wetted, and immediately before placing concrete, thoroughly broom, brush, or spray a thin (approximately ⅛ -in.) coating of bonding grout onto the saturated bridge deck. Use bonding grout that consists of equal parts, by volume, of Portland cement, microsilica (solids part) and mortar sand with sufficient water to form a slurry. Do not exceed water-to-cementitious ratio by weight of 0.40. Ensure that the consistency of the slurry facilitates the application in a thin, even coating that will not run or puddle. Do not retemper bonding grout. Broom bonding grout with straight push brooms at all joints and concrete surfaces around or below reinforcing steel. Ensure that all prepared surface areas receive a thorough, even coating, and that no excess bonding grout is permitted to collect in pockets. Coat all surfaces to be in contact with new concrete with the bonding grout. Limit the rate of bonding grout application to that surface area that can be covered with new concrete before the bonding grout begins to dry out. Ensure that the application of the bonding grout is not more than 5 ft from the leading edge of the overlay. If drying does occur, as evidenced by a light gray color, remove the bonding grout by sandblasting. Do not wet or spray the wet or dry bonding grout. Limitations of Mixing.
a.Temperature and Weather Conditions. Ensure that all weather and concrete temperature requirements meet Subsection 814.03.3 except as modified below.
b.C old Weather Concrete. Do not place Class HP concrete mixtures when ambient temperatures are below 45°F. However, the Class HP concrete may be placed at 45 °F when rising temperatures are forecast and if the forecast indicates temperatures over 45°F for a minimum period of eight hours after the placement has been completed. If the minimum air temperatures will not be met, the Contractor may place concrete if the structure is enclosed and external heat is provided to meet specified ambient temperature requirement for placement. At temperatures above 85°F, the Engineer may require placements to be made at night or in the early morning hours if a satisfactory surface finish is not being achieved. If any deviation from the approved Traffic Management Plan is necessary, a resubmittal is required.
c.Inclement Weather. For structures that are not enclosed, cease all placing operations when it starts to rain or snow. Placing and Finishing. Ensure that Class HP concrete overlay conform s to the placement requirements of Subsection 814.03.6 except as modified herein. Notify the Engineer before placement, and do not proceed
Part 800 — Bridge Structures August 2025
800-104 SECTION 816 — CONCRETE BRIDGE DECK OVERLAYS with concrete placement until receiving the Engineer’s approval. Complete the operation within the required scheduled time.
a.Finishing Machine. Ensure that the finishing machine conforms to Subsection 814.03.7.
b.Placement and Consolidation. Coordinate the concrete placement and initial strike-off so that initial strike-off is never more than 5 ft behind the concrete placement. Ensure that the concrete is consolidated with an approved high frequency (3000 to 7000 vpm) vibratory pan that is applied to secure maximum consolidation of the concrete. Use spud vibration in deep pockets, edges, and adjacent to joint bulkheads and overlays greater than 3 in. thick. Install a construction dam or bulkhead if a delay in the placement operations occurs exceeding 30 minutes duration. During delays of 30 minutes or less, protect the placement with presoaked wet burlap. If the concrete placement is stopped or delayed for 90 minutes or more, discontinue further placement. Separate screed rails and/or construction bulkheads from the newly placed material by passing a pointed trowel along their inside face. Do not separate metal expansion dams from the overlayment. Ensure that the trowel cut is made for the entire depth and length of rails after the mixture has sufficiently stiffened.
c.Finishing. Ensure that the finished surface, before texturing, is uniformly smooth, dense, and even. Variations in pavement surface in excess of ⅛ in. above or below the proper finished elevation or surface irregularities of more than ⅛ in. in 10 ft will not be accepted. Check the concrete surface according to Subsection 814.03.7(c). Hand finishing with a float may be required along the edge of the pour or on small areas or repair. Use edge tooling at joints, except next to metal expansion dams, curbs, and previously placed lanes. Testing. Field cure all compressive strength cylinders used for QC at the job site and under the same conditions as the Class HP concrete overlay. Curing Concrete. Ensure that the curing of Class HP concrete overlay conforms to Subsections 814.03.2 and 814.03.8, except as modified below. Do not allow any vehicular traffic on the Class HP concrete surface for a minimum period of 14 days and after the minimum specified 28-day design compressive strength is achieved.
Part 800 — Bridge Structures August 2025
SECTION 816 — CONCRETE BRIDGE DECK OVERLAYS 800-105 Grooving. Texture the final Class HP concrete deck overlay by transverse grooving that conforms to Subsection 814.03.9. Defective or Damaged Class HP Concrete. Repair or replace all defective or damaged HP concrete identified before the final acceptance of the work. Defects include: • Insufficient thickness • Cracking • Tearing • Honeycombing • Damage or other imperfections caused by the Contractor’s operations • Propose repair methods for approval by the Engineer
816.04 Method of Measurement.
Concrete Bridge Deck Overlay will be measured by the number of cubic yards of concrete placed.
816.05 Basis of Payment.
The Department will pay for the completed and accepted quantities as follows. Pay Item Pay Unit Concrete Bridge Deck Overlay CY The price constitutes full compensation for all labor, materials, equipment, surface preparation, bonding grout, grooving, and all incidentals required to finish the work and accepted by the Engineer.
Referenced in this section
Concrete Bridge Deck Overlays in other states
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Source: Standard Specifications for Road and Bridge Construction (Blue Book), 2022 (Aug 2025 compilation) Edition. Pages 471–474 of 951. View official source ↗