CONCRETE BRIDGE DECK REMOVAL
PART 1 GENERAL
1.1SECTION INCLUDES
A.Concrete bridge deck removal in preparation for replacing the entire
bridge deck.
1.2RELATED SECTIONS
A.Section 03924: Structural Concrete Repair
1.3REFERENCES
A.AASHTO/AWS D1.5 Bridge Welding Code
B.AASHTO LRFD Bridge Design Specifications
1.4DEFINITIONS Not Used
1.5SUBMITTALS
A.Working Drawings
1.Bridge Deck Removal Plan for review including at least the
following:
a.The proposed method of removal for deck, parapets, shear
studs and attachments such as drains and utilities as applicable. 1) Include the proposed method for preventing cutting into top flange. 2) Account for saw blade depth relative to actual deck thickness, haunch thickness, and top flange location
b.Precautions that will be used to protect portions of the
structure to remain
c.Written sequence of the specific steps for demolition
1) Include steps to remove the bridge deck in a safe and controlled manner.
d.Work area plan
1) Depict limits of removal and items such as utilities overhead and below the work area, drainage inlet structures, and protective measures. Concrete Bridge Deck Removal
e.Details of deck removal equipment and locations of use
1) Include details of equipment used to lift large portions of the deck such as cranes, excavators, lifting slings, sling hooks, and jacks. 2) Include crane locations, operation radii, and lifting calculations.
f.Methods for preventing damage and containing debris to
protect adjacent travelways, railroad facilities, waterways, property, utilities, and areas of the environment specified for protection 1) Include details and locations of protection and containment such as debris shields and water containment.
g.Supporting engineering calculations
1) Demonstrate the satisfactory stability and strength of the bridge under all anticipated loads and removal methods.
a.Account for the loss of composite action as the
bridge deck is being removed.
b.Consider the AASHTO LRFD dynamic load
allowance. 2) Demonstrate adequate strength for debris shields and containment.
h.Procedures for repairing girder damage such as cuts, nicks,
gouges, dents, bends, and spalls 1) Refer to this Section, Article 3.4.
i.Procedures for repairing damaged concrete girder stirrups.
j.Weld repair procedures meeting the requirements of
AASHTO/AWS D1.5 1) Include weld testing and grinding requirements.
k.Methods of debris disposal from the deck removal including
final disposal site
l.Schedule
1) Comply with all construction timeframes specified.
m.The seal of a Professional Engineer (PE) or Professional
Structural Engineer (SE) licensed in the State of Utah on drawings and calculations
Concrete Bridge Deck Removal
PART 2 PRODUCTS
2.1EQUIPMENT
A.Saw Cutting Equipment
1.Use saws capable of cutting through concrete and reinforcing steel
to the specified depth.
B.Machine Mounted Hydraulic or Pneumatic Equipment
1.Do not use directly over or within 6 inch of any portion of the girders
or abutment diaphragms, measured horizontally from the edge of flange or diaphragm.
C.Jackhammers
1.Limit the capacity of jackhammers within 6 inch of the existing
girders or abutment diaphragms, measured horizontally from the edge of flange or diaphragm.
a.Use 90 lb or smaller jackhammers.
b.Reduce the capacity of jackhammers if damage occurs to
the girders or diaphragms.
D.Hand Held Cutting Tools
1.Use cutting torches to cut existing reinforcing steel and shear
connectors that are required to be removed.
2.Use hand-held grinding equipment to remove portions of shear
connectors.
E.Other Equipment
1.Do not use unless authorized in the Bridge Deck Removal Plan.
PART 3 EXECUTION
3.1CONCRETE BRIDGE DECK REMOVAL PRE-ACTIVITY MEETING
A.Hold a pre-activity meeting after the Bridge Deck Removal Plan has been
authorized, but before starting the deck removal operations.
1.Hold a separate meeting for each bridge.
2.At least the following people must attend the pre-activity meeting:
a.Resident Engineer
b.Foreman and other supervisory personnel responsible for
deck removal
c.UDOT Assurance Testing Program Coordinator, or designee
(if existing girders are steel) Concrete Bridge Deck Removal
d.UDOT Structures representative
e.Engineer-of-Record
f.Railroad representative (as needed)
3.Conduct pre-activity meeting no more than seven calendar days
before each scheduled bridge deck removal.
4.Provide notification of the meeting to the Engineer at least seven
calendar days in advance.
5.Discuss at least the following items specific to the bridge deck
removal work:
a.Staging plan
b.Environmental requirements
c.Schedule, safety, quality control procedures, and verification
testing.
d.Authorized Bridge Deck Removal Plan
e.Debris containment equipment, placement, and methods.
f.Removal sequence and limits
g.Removal details (for example, between and above girders
and at diaphragms)
h.Location of monitors and communication with saw cutting
crew
i.Location of equipment (for example, cranes)
j.Special equipment
k.Cleanup and disposal
l.Contingency plans include but are not limited to the following
issues during construction: 1) Equipment break down 2) Superstructure damage 3) Weather delay requirements
6.Additional meetings may be required as determined by the
Engineer.
3.2PREPARATION
A.Mark the surface of the deck 6 inch away from the girder or abutment
diaphragms with marking paint to indicate zones requiring limited weight jackhammers.
B.Mark deck surface above steel girder splice locations to avoid cutting
concealed splice plates and bolts.
C.Provide the necessary protective devices to prevent damaging items
below and adjacent to the bridge. Including but not limited to:
1.Collect water used during deck removal.
2.Use debris shields and containment without cracks and openings
through which material may pass. Concrete Bridge Deck Removal
D.Inspection
1.Provide equipment that will facilitate inspection by UDOT
inspectors.
2.Notify the UDOT Assurance Testing Program Coordinator 7
calendar days before the first stages of bridge deck removal over steel girders.
3.Notify the Engineer of any damage to girders or other structural
elements.
3.3DECK REMOVAL
A.Follow the authorized Bridge Deck Removal Plan
B.Saw Cutting
1.Do not saw cut above the girder top flange sections above the
abutment diaphragm.
2.Limit the depth of longitudinal and transverse saw cuts above the
girder top flange to just below the bottom mat of reinforcing steel but not closer than 2 inch to the flange, splice plate or bolts.
a.Saw cuts no closer than 1 inch are permitted when bottom
mat of reinforcing steel is closer than 2 inch to the top flange, splice plate or bolts.
b.Coordinate the saw cuts that are closer than 2 inches to the
flange, splice plates, or bolts with the Engineer.
3.Continuously monitor the underside of the deck during the cutting
operation to prevent unexpected situations where the saw blade extends below the deck and could cut into the girder top flanges.
a.Maintain radio or visual contact between the monitoring
personnel and the cutting crew.
C.Concrete deck section removal near railroad
1.Lift slab sections using cranes or pavement removal buckets
mounted on hydraulic excavators when within 50 ft of a railroad track.
2.Perform removal procedures outside of the railroad minimum
construction clearance envelope shown.
D.Remove the concrete over the girder flange with jackhammers.
1.Provide alternate methods of concrete removal in the Bridge Deck
Removal Plan if alternate methods are desired.
2.Modify the removal process if damage occurs to the top flange,
diaphragms, splice plates, or bolts.
Concrete Bridge Deck Removal
E.Remove shear studs on steel girders.
1.Remove sufficient length to avoid conflict with new deck reinforcing
steel and shear studs.
a.Remnants up to ¾ inch may be left in place if there is no
conflict.
b.Do not damage flange if grinding smooth to top flange.
F.Protect stirrups in concrete girders in place.
1.Repair damaged stirrups as authorized by Engineer.
G.Protect intermediate diaphragms in place.
H.Clean top surfaces of girders.
1.Remove concrete, rust scale or other extraneous material from
steel girders.
2.Remove fractured and loose concrete from concrete girders.
3.4REPAIR DAMAGED STRUCTURE MEMBERS
A.Repair damaged girders and diaphragms according to the authorized
Bridge Deck Removal Plan. Use the following to develop the repair procedures:
1.Identify positive and negative moment regions.
2.Steel girder bridges
a.Repair bends and dents larger than ½ inch according to the
authorized Bridge Deck Removal Plan. 1) Smaller bends and dents need not be repaired.
b.Repair cuts, nicks and gouges less than or equal to 1/16 inch
deep for negative moment regions, and less than or equal to /16 inch deep for positive moment regions, by grinding; unless the damaged area reduces the total flange cross section by more than 2 percent. 1) Notify Engineer if damage is deeper than 1/16 inch for negative moment regions, and deeper than 3/16 inch for positive moment regions, or total flange cross section has been reduced by more than 2 percent.
c.Repair cuts, nicks and gouges greater than 1/16 inch deep for
negative moment regions, and greater than 3/16 inch deep for positive moment regions, according to the method described in the Bridge Deck Removal Plan.
d.Repair damaged webs, transverse vertical stiffeners, and
connection plates.
Concrete Bridge Deck Removal
3.Concrete Girder Bridges
a.Repair spalls 1½ inch or greater using an authorized
patching material 1) Spalls less than 1½ inch in the top flange need not be repaired provided that the area is to be filled with concrete or grout in the completed bridge deck.
b.Repair cracks in the top flange using epoxy injection crack
repair methods according to Section 03924.
c.Repair saw cuts that are deeper than ¼ inch by chipping out
the area and patching with an approved patching material. 1) Smaller saw cuts need not be repaired.
4.Develop special repair procedures for situations not defined in the
authorized Bridge Deck Removal Plan and obtain authorization before starting the repair procedure.
END OF SECTION
Concrete Bridge Deck Removal
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Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 912–918 of 1,331.
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