491 Page 360491 BRIDGE DECK POLYMER CHIP SEAL
491.1DESCRIPTION
This work consists of preparation of the plans specified existing bridge deck surface and furnishing and placing two coats of a polymer chip seal on the prepared bridge deck surface.
491.2MATERIALS
Materials will conform to the following Sections: A.Concrete Patching Material, Bridge Deck: Concrete patching material will be packaged, dry, rapid-hardening cementitious mortar or concrete materials conforming to the requirements of ASTM C 928, Type R-3 and will contain a bonding agent and will not contain any chlorides, magnesium, or phosphates. B.Water: Section 790 C.Polymer: Section 805 D.Cover Aggregate: Section 805
491.3CONSTRUCTION REQUIREMENTS
A.Surface Preparation 1.Removal and Replacement of Loose and Delaminated Concrete: a.Concrete Removal Classification: Concrete removal will be divided into one of the following two classes: 1)Concrete Removal, Class A: Concrete removal, Class A will consist of the removal of delaminated and visibly loose concrete and any bituminous patches (when present) from the top of existing bridge deck down to a depth no deeper than the top of the top bar in the top mat of bridge deck reinforcing steel. Unintentional concrete removal below the top of the top bar in the top mat of bridge deck reinforcing steel during the concrete removal, Class A process will be considered a part of concrete removal, Class A. 2)Concrete Removal, Class B: Concrete removal, Class B areas will be determined by the Engineer after completion of the concrete removal, Class A has been accomplished. Concrete removal, Class B will consist of the removal of delaminated and visibly loose concrete that exists below the bottom limits of the concrete removal, Class A (below the top of the top bar in the top mat of bridge deck reinforcing steel). b.Concrete Removal: Concrete removal will be accomplished by jackhammers and chipping hammers, or other methods as approved by the Engineer. Jackhammers and chipping hammers will be used as follows: 491 Page 3611)Jackhammers heavier than 30 pounds will not be permitted. 2)Chipping hammers heavier than 15 pounds will not be permitted for removing concrete below the top of the top mat of reinforcing steel. 3)Jackhammers and chipping hammers will not be operated at an angle in excess of 45 degrees measured from the surface of the concrete. 4)Extreme care will be taken when using jackhammers and chipping hammers to assure that existing reinforcing steel is not damaged or debonded from the sound concrete. Removal will begin near the center of the loose or delaminated concrete and will progress outwardly until the loose or delaminated concrete is removed and sound concrete is encountered such that the amount of concrete removal is minimized. The edges of removed concrete will be defined with a 3/4 inch deep saw cut where practical, as approved by the Engineer. If saw cutting is not practical, the use of jackhammers or chipping hammers may be required around the edges of the removal area to attain satisfactory results. Care will be taken during concrete removal to not nick, gouge, or in any other way damage the in place reinforcing steel. Any inadvertent damage to the in place reinforcing steel will be brought to the attention of the Department’s Bridge Construction Engineer and will be repaired by the Contractor as directed by the Engineer at no additional cost to the Department. c.Concrete Replacement: Upon completion of the concrete removal and immediately prior to placing any concrete patching material into the concrete removal areas, the removal areas will be thoroughly cleaned of loose and foreign material by abrasive blasting. The surface profile of the area to receive the concrete patching material will be in accordance with the manufacturer’s recommendations. The abrasive blasting will be to the extent that all surface laitance is removed. Abrasive blast cleaning will expose the coarse aggregate and remove rust from any exposed reinforcing steel. After abrasive blasting, the surface will be cleaned by the use of compressed air to the satisfaction of the Engineer. The air compressor used for cleaning will be equipped with trap devices capable of providing moisture-free and oil- free air at a pressure of 90 psi. The existing surface at the time of placement of the concrete patching material will be at least 40°F, measured by a thermometer placed against the concrete surface and covered with an insulating blanket. The concrete patching material will be mixed and placed in accordance with the manufacturer’s technical data sheet. The Contractor will provide a manufacturer’s technical data sheet to the Engineer prior to performing the work. The concrete patching material will be maintained at or above 45°F for at least 72 hours after placement. Immediately after finishing the concrete patching material, the surface of the concrete patching material will be covered with a double layer of wet curing blanket. Within one hour of covering with wet curing blanket, polyethylene sheeting will be placed on the 491 Page 362wet curing blanket. The surface will be wet cured for a minimum of 48 hours or in accordance with the manufacturer’s recommendations, whichever is more stringent. Following the wet cure, the curing blanket and polyethylene sheeting will be removed and the surface allowed to air dry for a minimum of 48 hours after removal of the curing blanket and polyethylene sheeting before application of the polymer chip seal is permitted. 2.Bridge Deck Grinding: If specified in the plans, the bridge deck surface will be ground prior to placement of polymer chip seal. The grinding will remove the existing surface conditions as defined by the plan notes including, but not limited to; epoxy chip seal, polymer chip seal, pavement markings, and tining to the satisfaction of the Engineer. The grinding will be performed in the longitudinal direction and will not damage bridge joints. The grinding will result in a parallel corduroy texture consisting of grooves between 0.090 and 0.130 inches wide. The distance between the grooves will be between 0.060 and 0.125 inches. The peaks of the ridges will not be greater than 1/16 inch higher than the bottom of the grooves. The grinding will be uniform and will follow the existing profile of the bridge deck. The grinding process will not introduce dips and bumps that did not previously exist on the bridge deck surface or in any way decrease the existing ride quality of the bridge deck. Grinding of the bridge deck will be accomplished utilizing diamond blades mounted on a self- propelled machine designed for grinding and texturing pavement. The equipment will be operated in such a manner that it will not damage the underlying deck surface. Grinding equipment that causes ravels, aggregate fractures, or spalls will not be permitted. Residue or excess water generated by the grinding operations will be removed with vacuum equipment from the deck surface before the residue has time to set up. Vacuumed residue or excess water will not be expelled on the approach roadway or shoulder surfaces. 3.Abrasive Blasting of Bridge Deck: After grinding, the entire bridge deck surface will be thoroughly shot blasted to International Concrete Repair Institute (ICRI) concrete surface profile CSP-5 (medium shot blast) to remove all foreign materials which may interfere with the bonding or curing of the polymer chip seal. The shot blasting will remove all surface laitance and will expose the coarse aggregate to the satisfaction of the Engineer. Small areas where shot blasting is unable to be performed (curb lines, etc.) will be cleaned by abrasive blast cleaning to the satisfaction of the Engineer. Upon completion of the shot blasting and abrasive blasting, the entire bridge deck will be blown clean with dry compressed air to remove all dust and debris. Cleaning by shot blasting, abrasive blasting, and compressed air will be done no more than 24 hours prior to the placement of the polymer chip seal. In the event that the polymer chip seal is not placed within 24 hours of shot blasting and abrasive blast cleaning or in the event of rain or other inclement weather contaminating the surface, the surface will be re-cleaned by abrasive blast cleaning and dry compressed air. 491 Page 363Only equipment required for the application of the polymer chip seal will be allowed on any portion of the bridge deck which has been cleaned and prepared for application of the polymer chip seal. If equipment is used on the cleaned and prepared bridge deck, the area will be protected from contamination with plastic. B.Bridge Deck Polymer Chip Seal 1.Seasonal Limitations: Polymer chip seals will only be applied within the seasonal limitation of May 1 to October 15 (inclusive). 2.Manufacturer’s Representative: A manufacturer approved representative will be present on the jobsite for the first two full production days of the polymer chip seal. The representative will provide technical expertise to the Contractor and Engineer regarding the safe handling, correct placement, and proper curing of the polymer chip seal. The manufacturer’s representative will provide the Engineer and the Contractor a copy of the written application recommendations, technical data sheet, and product safety data sheet. In addition, the Contractor will make a product safety data sheet available to anyone that will be exposed to the polymer materials. If the Contractor has a minimum of 100,000 square yards of experience with the polymer being used, the Manufacturer’s Representative will not be required to be on the jobsite. 3.Polymer Application Requirements: The Contractor will store, mix, handle, and apply the polymer in accordance with the manufacturer’s recommendations, or as approved by the Engineer, unless otherwise specified by the following requirements: a.Polymer will not be applied unless the ambient air temperature and the application area surface temperature is between 50°F and 100°F with the air temperature at least 5°F above the dew point temperature. In addition, the forecast for the duration of the application period plus four hours after the anticipated completion of the chip seal application will be such that no rain is expected, and temperatures are forecasted to be between 50°F and 100°F with the air temperature at least 5°F above the dew point temperature. b.The application of the polymer chip seal system will not be made on a wet or damp surface. In the event of rain, the surface will be dried for 24 hours prior to application. In lieu of waiting the 24 hours, ASTM D 4263 “Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method” may be used to determine when all moisture is out of the concrete. The use of a surface moisture meter to determine surface conditions will not be allowed. c.The openings of any bridge deck drains will be temporarily sealed during polymer placement as approved by the Engineer. d.The surfaces of existing bridge joints will be masked with duct tape or other material, as approved by the Engineer. The masking will be completely removed before the polymer achieves initial set. Removal will not damage the adjacent polymer or the surface of the underlying joint. 491 Page 364e.When phased construction of the polymer chip seal is required, the Contractor will maintain a straight line between the phases of polymer placement for both layers by masking the line between phases with duct tape, or other material approved by the Engineer. The masking will be completely removed before the polymer achieves initial set and will be removed in a manner that will not damage the adjacent polymer. Overlapping the new polymer chip seal onto existing polymer chip seal will not be done. f.Prior to mixing, the application area will be marked in a grid to ensure proper spread rates are achieved. g.A prime coat, if required by manufacturer, will be applied according to manufacturer’s recommendations and will be applied in addition to the two coats of polymer chip seal. h.A coat of polymer will be distributed at the manufacturer’s recommended application rate. The application rate will be a minimum of 1 gallon per 40 square feet. 4.Cover Aggregate Application Requirements : a.After the polymer is distributed on the application area, a broadcast of cover aggregate will be made to refusal such that: 1)A uniform layer of cover aggregate is attained. (A non-uniform broadcast will result in an inconsistent polymer chip seal thickness and a poor ride). 2)There are no visible shiny wet spots after application. b.Broadcasting will be done by hand-seeding or other methods approved by the manufacturer’s representative such that the following conditions are met: 1)The aggregate falls vertically to the application area surface to prevent pushing of the polymer resin. 2)Aggregate coverage is uniform over the application area. 5.Clean up of Excess Cover Aggregate Requirements: The polymer will be allowed to cure before excess cover aggregate is removed. Cure the polymer for 2 to 6 hours depending on temperature or based on the manufacturer’s recommendations before removing excess cover aggregate. The polymer must have sufficient strength to retain aggregate. Excess aggregate will be removed by brooming, high pressured dry air, or vacuuming and will be disposed of by the Contractor as approved by the Engineer. 6.Second Coat Application: A second coat of polymer will be distributed at the manufacturer’s recommended application rate. The application rate will be a minimum of 1 gallon per 20 square feet. Cover aggregate will be broadcast as per Section 491.3 B.4. In the event of rain before second coat is applied, the surface will be dried 24 hours prior to application. If second coat is not applied within 24 hours or traffic is allowed on the first coat, the application area must be abrasive blasted prior to application. 491 Page 3657.Testing: Pull-off tests will be performed after the final coat of polymer chip seal is cured and excess aggregate is removed to verify adequate bond strength of the polymer to the cover aggregate and concrete substrate. Pull-off tests will be performed by the Contractor and will be witnessed by the Engineer. Placement of the pull-off test will be randomly selected by the Engineer and will not be located within 1 foot of the barrier curb. The pull-off test will be performed prior to opening to traffic. Pull-off tests may not be performed when the surface temperature is at or above 90°F. One pull-off test will be performed for each 75 linear feet of polymer chip seal application width, up to 24 feet wide, for each structure. A minimum of 3 pull- off tests will be required for each structure. The testing will be performed as follows: a.Pull-off tests will be performed according to ASTM D7234. b.Pull-off tests with a resulting load of 250 psi or more will be considered passing. c.All pull-off tests with a resulting load of less than 250 psi will be retested according to the type of failure. There are four possibilities or combinations thereof as described below: 1)Failure in the concrete substrate (concrete failure) - The Contractor will perform one additional test within 1 foot of the failing test to verify concrete failure. 2)Detaching assembly adhesive failure (adhesive failure) - The Contractor will perform one additional test within 1 foot of the failing test. The Contractor will repeat the test until the adhesive no longer fails. 3)Separation of the polymer chip seal from the concrete surface (polymer failure) - the Contractor will perform two additional pull-off tests as described below. 4)Pullout of the aggregate from the polymer (polymer or aggregate failure) - The Contractor will perform two additional pull-off tests as described below. For failure 3 or 4, the Contractor will perform two additional pull-off tests. One test will be performed between 10 feet and 15 feet back from the failing test and one test will be performed between 10 feet and 15 feet ahead of the failing test. If either of these two additional pull-off tests fails, the polymer chip seal fails and the failing polymer chip seal will be removed and replaced at the Contractor’s expense. The limits of the failing polymer chip seal will be defined as the polymer chip seal one-half of the distance back and one-half of the distance ahead to the adjacent passing tests. When the detaching assembly has been separated from the surface, the damage created by the test will be repaired using a small amount of the polymer and aggregate used in the polymer chip seal.
491.4METHOD OF MEASUREMENT
A.Remove and Replace Deteriorated Concrete: Removal of deteriorated concrete will be measured by the class of concrete removal. Replacement of deteriorated concrete will be measured by the concrete patching material, bridge deck item. 491 Page 3661.Concrete Removal, Class A: Concrete removal, Class A will be measured to the nearest 0.1 foot and the area computed to the nearest 0.1 square yard. 2.Concrete Removal, Class B: Concrete removal, Class B will be measured to the nearest 0.1 foot and the area computed to the nearest 0.1 square yard. 3.Concrete Patching Material, Bridge Deck: Concrete patching material, bridge deck will be measured to nearest 0.1 cubic feet as determined from the theoretical yield per bag of concrete patching material. B.Bridge Deck Grinding: Measurement will not be made for bridge deck grinding. The plan quantity will be the basis of payment. C.Abrasive Blasting of Bridge Deck: Measurement will not be made for abrasive blasting of bridge deck. The plan quantity will be the basis of payment. D.Two Coat Bridge Deck Polymer Chip Seal: Measurement will not be made for two coat bridge deck polymer chip seal. The plan quantity will be the basis of payment. E.Pull-Off Test: Measurement will not be made for pull-off tests.
491.5BASIS OF PAYMENT
A.Remove and Replace Deteriorated Concrete: Removal of deteriorated concrete will be paid for under the class of concrete removal. Replacement of deteriorated concrete will be paid for under the concrete patching material, bridge deck item. 1.Concrete Removal, Class A: Concrete removal, Class A will be paid for at the contract unit price per square yard. Payment will be full compensation for all labor, equipment, materials, and all incidental work required to remove the specified concrete, concrete sawing, and disposing of removed material. 2.Concrete Removal, Class B: Concrete removal, Class B will be paid for at the contract unit price per square yard. Payment will be full compensation for all labor, equipment, materials, and all incidental work required to remove the specified concrete, concrete sawing, and disposing of removed material. 3.Concrete Patching Material, Bridge Deck: Concrete patching material, bridge deck will be paid for at the contract unit price per cubic foot. Payment will be full compensation for all labor, equipment, materials, and all incidental work required to abrasive blast clean the removal areas, and furnish, place and cure the concrete patching material within the removal areas. B.Bridge Deck Grinding: Bridge deck grinding, when specified in the plans, will be paid for at the contract unit price per square yard. Payment will be full compensation for all labor, equipment, materials, and all incidental work required to grind the bridge deck surface to the required profile and to remove and dispose of the grinding residue and water. C.Abrasive Blasting of Bridge Deck: Abrasive blasting of bridge deck will be paid for at the contract unit price per square yard. Payment will be full compensation for all labor, 491 Page 367equipment, materials, and all incidental work required to shot blast and abrasive blast clean the bridge deck surface of all foreign materials and to remove and dispose of all residues. D.Remove and Replace Deteriorated Concrete: Remove and Replace Deteriorated Concrete, when specified in the plans, will be paid for at the contract unit price per square yard. Payment will be full compensation for equipment, materials, labor and incidentals necessary to remove loose, deteriorated concrete or bituminous material, cleaning removal areas, disposal of removed materials and furnishing, placing and curing new concrete place within the removal areas. E.Two Coat Bridge Deck Polymer Chip Seal: Two coat bridge deck polymer chip seal will be paid for at the contract unit price per square yard. Payment will be full compensation for all labor, equipment, materials, and all incidental work required to furnish and install the two coat bridge deck polymer chip seal and to remove and dispose of the excess cover aggregate. Payment will also be full compensation for all manufacturer approved representative expenses. F.Pull-Off Test: No payment will be made for pull-off tests. All costs related to the testing for labor, test equipment, laboratory, tools and all incidentals required to satisfactorily perform the required work will be incidental to the contract unit price for two coat bridge deck polymer chip seal. 510 Page 368510 TIMBER, PRESTRESSED, AND STEEL PILES
510.1DESCRIPTION
This work consists of furnishing, driving, and cutting off timber, prestressed, and steel piling; and furnishing, driving, cutting off, and fastening of sheet piling and steel sheeting designated to be left in place.
510.2MATERIALS
Materials will conform to the following requirements: A.Timber Piles: Section 960. B.Steel Piles: ASTM A572, Grade 50. C.Sheet Piles: Section 1040 . D.Steel Sheeting: Section 1050 . E.Prestressed Piles: Section 560.
510.3CONSTRUCTION REQUIREMENTS
A.Preparation for Driving Steel and Timber Pile: 1.Caps: The heads of timber piles will be protected by approved caps if driving is likely to damage the pile. When the area of the head of any timber pile is greater than that of the face of the hammer, a suitable cap will be provided to distribute the hammer blow throughout the cross section of the pile. The head will be cut square and shaped or chamfered to prevent splitting at its periphery. The heads of steel piles will be cut squarely, and a driving cap will be provided to hold the axis of the pile in line with the axis of the hammer. 2.Collars: Collars, bands, or other devices to protect timber piles against splitting and brooming will be provided where necessary. 3.Pointing: When specified, timber piles will be shod with metal shoes in accordance with the plans. The points of the piles will be carefully shaped to secure an even and uniform bearing on the shoes. After shaping, exposed untreated wood will be retreated in the field in accordance with Section 510.3 G. 4.Splicing Piles: Splices will be made in accordance with the details. Indiscriminate use and location of splices is prohibited. The proposed location of splices used in conjunction with frame pile bents and integral type abutments will require prior approval. All splices will be welded by a certified welder in accordance with Section 410.