544PREFABRICATED BRIDGE UNIT SUPERSTRUCTURE

544

5-332SECTIO N 544 – PREFABRICATE D BRIDG E UNIT SUPERSTRUCTURE

544.0 1 DESCRIPTION . This work shall consist of manufacturing, transporting, and erecting concrete and steel composite Prefabricated Bridge Units (PBUs) as shown on the Plans. The work under this section shall be performed in accordance with these provisions, the Plans, and Section 501, Section 506 , Section 507 , and Section 508 . 544.0 2 MATERIALS . Materials shall meet the material requirements specified in Subsection 501.02 , Subsection 506.02 , Subsection 507.02 , and Subsection 508.02 . 544.0 3 GENERA L FABRICATIO N REQUIREMENTS . The structural steel furnished under this section shall be fabricated in a p lant meeting the requirements of Subsection 506.03 . After fabrication, the structural steel shall be transported to a location approved by the Agency where the steel will be shop galvanized , metallized , or painted, or where the remainder of the composite superstructure unit will be fabricated. The fabricator or Contractor constructing the reinforced concrete portion of the PBUs shall have demonstrated experience in forming, casting, curing, and finishing performance -based concrete superstructure decks in accordance with Section 501 . 544.0 4 SUBMITTALS . As soon as practical after award of the Contract, all required information shall be prepared and submitted. Fabrication drawings and erection plans shall be su bmitted as separate submittals. Fabrication drawings for the PBUs shall be submitted in accordance with Subsection 105.06 . In addition to the requirements for fabrication drawings in Subsection 105.06 , the following shall be included:

inserts . Reinforcing steel material lists, material designations, and bending details shall also be included.

of Subsection 501.1 5.

544 5-333 (f) Temporary assembly plan and procedure .

Lifting attachments are not required to be permanently installed in the work and may be removed or left in place at the Contractor’s convenience, provided that the minimum clear cover is met.

will not be cracked or damaged by handling or transport. A professional engineer shall stamp all calculations. 544.0 5 INSPECTION . Structural steel shall be inspected by the Agency in accordance with Subsection

106.04and Section 506

Concrete elements furnished and the work performed herein shall be inspected by the Agency. The inspector shall have the authority to reject any material or work that does not meet the requirements of these specifications. Advance notification of at least 14 calendar days shall be provided by the Contractor to the Engineer and the Structural Concrete Engineer concerning the proposed intention to commence work. A minimum notification of 5 working days shall be provided by the Contractor to the Engineer and the Structural Concrete Engineer to confirm the fabrication start date. 544.0 6 FABRICATION .

Relative bearing elevations shall be within ± 0.01 feet of that shown on the Plans.

diaphragms shown on the Plans shall be installed prior to placing any concrete formwork.

507.

Performance -Based Concrete, Class PCD. Concrete shall be produced and te sted in accordance with Subsection 501.04 through Subsection 501.07 .

544 5-334 (f) Pre-Production Meeting . Unless the Engineer deems, in writing, that a pre -production meeting is unnecessary, then a pre -production meeting shall be held a minimum of 7 calendar days prior to beginning concrete placement. The pre -production meeting shall be attended by, but not be limited to, the crew supervisor, Contractor project manager, concrete producer, Engineer , Construction Structures Engineer, and Project Manager .

Concrete shall not be deposited in the forms until the Agency representative has approved placement o f the reinforcement and inserts. The concrete shall be vibrated internally, externally, or a combination thereof to the required consolidation. The vibrating shall be done with care and in such a manner that:

lengths shall not vary by more than 3/4 inch ).

544 5-335 f. The tolerance for g irder spacing within a unit shall be ± 1/2 inch .

line parallel to the centerline of the unit, shall be ± 3/8 inch .

inch.

not exceed 1/4 inch.

specifications

determined by t he Engineer

544 5-336 (m) Repairing and Patching . Units that contain minor defects caused by manufacture or handling may be repaired at the manufacturing site. Minor defects are defined as holes, honeycombi ng, or spalls which are 6 inches or less in diameter and do not penetrate deeper than 1 inch into the concrete. Surface voids or bug holes that are less than 5/8 inch in diameter and less than 1/4 inch deep need not be repaired. Repairs shall be made using an overhead and vertical concrete repair material satisfactory to the Engineer. The repair material shall be cured as specified by the manufacturer. Repairs shall be approved by the Engineer.

Agency approved materials and procedures. Crack widths measuring 0.01 inch to 0.03 inch in width shall be epoxy injected using Agency approved materials and procedures. At the Engineer’s discretion, cracked members sh all be repaired or replaced at the Contractor’s expense.

vicinity of the upstation end diaphragm) with the following information:

period is complete and the concrete has reached full design strength.

between adjacent units before shipping to the project site, to the satisfaction of the Agency.

been stamped by the Agency. The Contractor shall give the Engineer 48-hours’ advance d notice of the loading and shipping schedule. The units shall be secured on the vehicle in order that no fatigue cracking will occur during tran sport. The Contractor shall secure the necessary hauling permits. 544.0 7 HANDLING . PBUs shall be handled, stored, and shipped in such a manner as to minimize chipping, cracks, fractures, discoloration, and excessive bending stresses. Units damaged by ha ndling, storage, or shipping shall be replaced at the Contractor’s expense. Field cured test cylinders for production site handling and shipping strength verification purposes shall be tested either at the Agency’s Materials Testing and Certification Section Central Laboratory or at an independent laborat ory approved by the Engineer. An Agency representative shall witness all tests.

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5-337If an independent lab is proposed to be used to test the field cured cylinders, the Contractor shall submit

documentation p roviding verification for the following:

Section 5

The Agency at any time reserves the right to perform an independent proficiency of the technician for the test methods used and review of the testing facility. 544.0 8 INSTALLATION .

the specifications for each respective item. Construction procedures and p ermissible variations other than those contained herein shall be submitted for approval.

design and capacity to safely erect, align, and secure all membe rs and components in their final positions without damage. The Contractor is solely responsible for the methods and equipment employed for the erection of the PBUs. The Contractor shall submit construction drawings in accordance with Subsection 105.06 for the methods and sequence of PBU erection, the temporary bracing, and the equipment to be used for the erection. The erection plan shall include the necessary computations to indicate the magnitude

of stress in the segments during erection and to demonstrate that all of the erection equipment has

adequate capacity for the work to be performed. The erection plan shall contain provisions for all

stages of construction, including temporary stoppages.

The PBUs may be used to support equipment prior to placement of the closure pour concrete only

with written permission of the Engineer. The proposed use of the PBUs for support of equipment

shall be detailed in the erection plan.

Submittal of the erection plan is for documentation purposes only and shall in no way be construed

as approval of the proposed method of erection. Unless otherwise directed by the Engineer, the

Contractor shall follow the erection plan as submitted.

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for the minimum length of time specified in the Plans or appropriate specifications. Units shall be

installed to the correct line and grade as shown on the approved drawings and as indicated in the

approved erection procedure. Prior to setting units and to avoid torsion stresses, bearing elevations

within a given PBU shall be adjusted to match relative elevations used during the deck casting

operations. After all the units are erected, they shall be inspected to ensure the correctness of their

location.

vertically (along longitudinal edges) and 1/4 inch vertically at the end of units.

material, the surface of the joint shall be free of any material, such as oil, grease, or dirt, which

may prevent bonding of the sealing materials.

and the lifting holes filled with a Type IV mortar. A removable form shall be provided at the

bottom surface of the deck to retain the grout.

permission of the Engineer and in accordance with the approved erection procedure. Once the

joints are sealed, no further loading or unloading of the units will be allowed until the joint material

has properly and finally cured and as approved by the Engineer.

and lifting holes shall be repaired as indicated and approved by the Engineer.

544.09METHOD OF MEASUREMENT. The quantity of Prefabricated Bridge Unit Superstructure to

be measured for payment will be the number of linear feet installed in the complete and accepted work.

Measurement will be the end-to-end length of the structural steel girder along the centerline per unit.

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544.10BASIS OF PAYMENT. The accepted quantity of Prefabricated Bridge Unit Superstructure will

be paid for at the Contract unit price per linear foot. Payment will be full compensation for detailing,

fabricating, repairing, quality control testing, transporting, handling, and installing the materials specified,

including concrete, reinforcing steel, structural steel, shear connectors, mechanical connectors, and shims;

for designing and installing lifting devices and any other material contained within or attached to the

members; for any grouting work required; for furnishing and implementing the erection plan; and for

furnishing all labor, tools, equipment, and incidentals necessary to complete the work.

Payment will be made under:

Pay Item Pay Unit

00 Prefabricated Bridge Unit Superstructure .................................................Linear Foot

546

5-340SECTIO N 546 – PRE-EXCAVATIO N OF ABUTMEN T PILES

546.0 1 DESCRIPTION . This work shall consist of drilling a hole to remove all subsurface material and backfilling in designated areas to provide suitable pile placement or driving conditions. 546.0 2 MATERIALS . Materials shall meet the requirements of the following subsections: Sand Borrow and Cushion ................................ ................................ ......................... 703.03 546.0 3 CONSTRUCTIO N REQUIREMENTS . The pre -excavation of abutment piles shall consist of augering, pre -boring, or some other means of excavation to produce an excavation to the depth and diameter specified in the Cont ract. The excavation shall be maintained to allow for backfilling with sand in accordance with the Contract . Temporary casing will be considered an acceptable option. Unless otherwise specified in the Plans, the entire pre -excavation shall be filled with sand and the temporary casing shall be removed prior to installing piles. 546.0 4 DEFINITIONS .

packed gravel will be considered excavation of earth.

546.0 5 METHO D OF MEASUREMENT . The quantities of Pre -Excavation of Abutment Piles, Earth and Pre-Excavation of Abutment Piles, Rock to be measured for payment will be the total number of linear feet of excavation to the depth specified in the Contract or as ordered by the Engineer, measured to the nearest linear foot.

separately at the same location, measurement for Pre -excavation of Abutment Piles, Earth will be made only below the lower limits of Structure Excavation.

be below the top surface of bedrock as determined by the Engineer.