6-02Concrete Structures

6-02 Concrete Structures6-02 Concrete Structures

6-02.1 Description

This Work consists of the construction of all Structures (and their parts) made of portland cement or blended hydraulic cement concrete with or without reinforcement, including bridge approach slabs. Any part of a Structure to be made of other materials shall be built as these Specifications require elsewhere.

6-02.2 Materials

Materials shall meet the requirements of the following sections: Cement 9-01 Aggregates for Concrete 9-03.1 Gravel Backfill 9-03.12 Joint and Crack Sealing Materials 9-04 Threaded Anchor Rods, Nuts, and Resin Bonding Material 9-06.4 Strip Seal Expansion Joint Components 9-06.19(1) Modular Expansion Joint Components 9-06.19(2) Reinforcing Steel 9-07 Epoxy-Coated Reinforcing Steel 9-07 Pigmented Sealer Materials 9-08.3(1) Exposed Aggregate Concrete Coatings and Sealers 9-08.3(2) Permeon Treatment 9-08.3(3) Grout 9-20.3 Mortar 9-20.4 Curing Materials and Admixtures 9-23 Fly Ash 9-23.9 Ground Granulated Blast Furnace Slag 9-23.10 Microsilica Fume 9-23.11 Plastic Waterstop 9-24 Water 9-25 Fabricated Bridge Bearing Assemblies 9-31

6-02.3 Construction Requirements

6-02.3(1) Classification of Structural Concrete

The class of concrete to be used shall be as noted in the Plans and these Specifications. The class includes the specified minimum compressive strength in psi at 28 days (numerical class) and may include a letter suffix to denote structural concrete for a specific use. Letter suffixes include A for bridge approach slabs, D for bridge decks, P for piling and shafts, and W for underwater. The numerical class without a letter suffix denotes structural concrete for general purposes. Concrete of a numerical class greater than 4000 shall conform to the requirements specified for either Class 4000 (if general-purpose) or for the appropriate Class 4000 with a letter suffix, as follows:

6-02.3(2)A1 .

6-02.3(2) Proportioning Materials

The soluble chloride ion content shall be determined by the concrete supplier and included with the mix design. The soluble chloride ion content shall be determined by

6-02 Concrete StructuresAs an alternative to the use of fly ash, ground granulated blast furnace slag and cement

as separate components, a blended hydraulic cement that meets the requirements of Section 9-01.2(1)B Blended Hydraulic Cements may be used.

6-02.3(2)A Contractor Mix Design

The Contractor shall provide a mix design in writing to the Engineer for all classes of concrete specified in the Plans except for lean concrete Type 2, commercial concrete and concrete class EA. No concrete shall be placed until the Engineer has reviewed the mix design. The required average 28-day compressive strength shall be selected in accordance with ACI 301, Chapter 4, Section 4.2.3.3. ACI 211.1 shall be used to determine proportions. All proposed concrete mixes except Class 4000D shall meet the requirements in Cementitious Requirement for Concrete in Section 6-02.3(2) . The Contractor’s submittal of a mix design shall be on WSDOT Form 350-040 and shall provide a unique identification for each mix design. A unique identification for the mix design is comprised of the combination of the Mix Design Number and the Concrete Plant Number. The mix design shall include the mix proportions per cubic yard, the proposed sources, the average 28-day compressive strength for which the mix is designed, the fineness modulus, and the water cement ratio. The mix design submittal shall also include test results no older than one year showing that the Aggregates do not contain Deleterious Substances in accordance with Section 9-03 . Concrete placeability, workability, and strength shall be the responsibility of the Contractor. The Contractor shall notify the Engineer in writing of all mix design modifications. Fine aggregate shall conform to Section 9-03.1(2) Class 1 or Class 2. Coarse aggregate shall conform to Section 9-03 . An alternate combined aggregate gradation conforming to Section 9-03.1(5) may also be used. The nominal maximum size aggregate for Class 4000P shall be ⅜ inch. The nominal maximum size aggregate for Class 4000A shall be 1 inch. Nominal maximum size for concrete aggregate is defined as the smallest standard sieve opening through which the entire amount of the aggregate is permitted to pass. A retarding admixture is required in concrete Class 4000P. Air content for concrete Class 4000D shall conform to Section 6-02.3(2)A1 . For all other concrete, air content shall be a minimum of 4.5 percent and a maximum of 7.5 percent for all concrete placed above the finished ground line unless noted otherwise.

6-02.3(2)A1 Contractor Mix Design for Concrete Class 4000D

All Class 4000D concrete shall conform to the following requirements:

6-02.3(2)A2 Contractor Mix Design for Self-Consolidating Concrete

Self-consolidating concrete (SCC) is concrete that is able to flow under its own weight and completely fill the formwork without the need for vibration while maintaining homogeneity, even in the presence of dense reinforcement. SCC shall be capable of being pumped, and of flowing through the steel reinforcing bar cage without segregation or buildup of differential head inside or outside of the steel reinforcing bar cage. Type III cement may be used in SCC. SCC may be used for the following concrete Structure elements:

6-02 Concrete Structures2. Column Segregation.

6-02.3(2)B Commercial Concrete

Commercial concrete shall have a minimum compressive strength at 28 days of 3,000 psi in accordance with AASHTO T 22. Commercial concrete placed above the finished ground line shall be air entrained and have an air content from 4.5 percent to 7.5 percent in accordance with FOP for AASHTO T 152. Commercial concrete does not require mix design or source approvals for cement, aggregate, and other admixtures. Where concrete Class 3000 is specified for items such as, culvert headwalls, plugging culverts, concrete pipe collars, pipe anchors, monument cases, Type PPB, PS, I, FB and RM signal standards, pedestals, cabinet bases, guardrail anchors, fence post footings, sidewalks, concrete curbs, curbs and gutters, and gutters, the Contractor may use commercial concrete. If commercial concrete is used for sidewalks, concrete curbs, curbs and gutters, and gutters, it shall have a minimum cementitious material content of 564 pounds per cubic yard of concrete, shall be air entrained, and the tolerances of Section

6-02.3(5)C shall apply.

M 41-10 Page 6-11 Concrete Structures 6-026-02.3(2)C Concrete Class EA Concrete for members and surfaces specified to receive an exposed aggregate finish shall be Class EA. Concrete Class EA shall conform to the following requirements: 28 day compressive strength 3,600 psi (minimum) Cement 610 pounds per cubic yard Fine Aggregate Class 1 880 pounds per cubic yard Coarse Aggregate Grading No. 67 2,160 pounds per cubic yard Water (maximum) 270 pounds per cubic yard Water/Cement Ratio (maximum) 0.44 A Type A water reducing admixture conforming to Section 9-23.6 shall be used in accordance with Section 6-02.3(3) . Air content shall conform to Section 6-02.3(2)A . Mixing water shall be the minimum required for satisfactory placement and shall not exceed the specified amount. Aggregate weights are based on a specific gravity of 2.67. Adjustments in the mix design will be made by the Engineer as necessary to correct for actual bulk specific gravity of the aggregates, moisture content of the aggregates, and to ensure proper consistency, workability, and correct cement content per cubic yard of concrete.

6-02.3(2)D Lean Concrete

Lean concrete Type 1 and lean concrete Type 2 are self-compacting, cementitious, flowable material requiring no subsequent vibration or tamping to achieve consolidation. Unless otherwise provided, when the specifications refer to “lean concrete” without being designated as Type 1 or Type 2, it shall be understood as meaning either lean concrete Type 1 or lean concrete Type 2, subject to their respective restrictions on use (found in other sections). Lean concrete Type 1 or Type 2 shall meet the following requirements: Requirements for Lean Concrete Lean Concrete Type 1 (See note 1) Lean Concrete Type 2 Min. 28 Day Strength 100 psi N/A Max. 28 Day Strength 300 psi N/A Max. water/cementitious content 2.0 2.0 Air Content Not specified Not specified Basis for AcceptanceCertification of Compliance

6-02.3(5)BCertification of Compliance

6-02 3(5)B

Is Vibration Required No No Is a mix design submittal required? Yes No Consistency RequirementPumpable and flowable (approximate slump 6 to 10 inches)Flowable (approximate slump 6 to 10 inches) Batching Requirements Meet 6-02.3(4) Meet 6-02.3(4) Minimum Cementitious Content (Pounds) No minimum specified 145 Maximum Cementitious Content (pounds) No maximum specified 200 Page 6-12 M 41-10

6-02 Concrete StructuresRequirements for Lean Concrete

Lean Concrete Type 1 (See note 1) Lean Concrete Type 2 Minimum percent Replacement of Fly Ash or Ground Granulated Blast Furnace Slag for Portland Cement No minimum specified No minimum specified Maximum percent Replacement of Fly Ash for Portland Cement No maximum specified 30 Maximum percent Replacement of Ground Granulated Blast Furnace Slag for Portland Cement No maximum specified 50 Note 1: The Contractor shall submit a mix design for lean concrete Type 1 on WSDOT Form 350- 040, as a Type 2 Working Drawing in accordance with Section 1-05.3, and shall provide a unique identification for the mix design. A unique identification for the mix design is composed of the combination of the Mix Design Number and the Concrete Plant Number. The mix design shall include the mix proportions per cubic yard, the proposed sources, the water cement ratio, and supporting strength test data. The mix design may be developed using, as a guideline, ACI 229R, Report on Controlled Low-Strength Materials, with the understanding that the requirements of Section 6- 02.3(2)D take precedence over conflicts with ACI 229R. Additionally, the mix design submittal shall include at least 15 consecutive sets of 28-day compressive strength tests (using ASTM D4832), which demonstrate that the mean and standard deviation provide not less than an 80% probability that tests will be between the minimum and maximum strengths specified. No lean concrete Type 1 shall be placed until the Engineer has reviewed and commented on the mix design.

6-02.3(3) Admixtures

Concrete admixtures shall be added to the concrete mix at the time of batching the concrete or in accordance with the manufacturer’s written procedure and as accepted by the Engineer. A copy of the manufacturer’s written procedure shall be furnished to the Engineer prior to use of admixtures. Deviations from the manufacturer’s written procedures shall be submitted as a Type 2 Working Drawing. Admixtures shall not be added to the concrete with the modified procedures until the Engineer has concurred in writing. When the Contractor is proposing to use admixtures from different admixture manufacturers they shall provide evidence to the Engineer that the admixture will be compatible and not adversely affect the air void system of the hardened concrete. Test results complying with ASTM C457 shall be provided as the evidence to satisfy this requirement. Admixture combinations which have been previously tested and which are in compliance with ASTM C457 shall be listed in the Qualified Products List (QPL). Proposed combinations not found in the QPL shall meet this requirement. Accelerating admixtures conforming to Sections 9-23.6(4) or 9-23.6(6) and used in accordance with the manufacturer’s recommendations may be used in cast-in-place concrete, except as required here. Accelerating admixtures shall not be used in bridge decks, all concrete superstructures, crossbeams, columns, mass concrete, or new bridge approach slabs and expansion joints that are not part of a repair. Concrete placements with the least dimension greater than 6 feet shall be considered mass concrete. Concrete placement with the least dimension greater than 3 feet, but less than or equal than 6 feet, shall require the approval of the Engineer for the use of accelerating admixtures. Shafts shall not be considered mass concrete. Chloride based accelerating admixtures shall not be used. Air entrained cement shall not be used to air entrain concrete. M 41-10 Page 6-13 Concrete Structures 6-026-02.3(4) Ready-Mix Concrete All concrete, unless otherwise specified, shall be batched in a prequalified manual, semi- automatic, or automatic plant as described in Section 6-02.3(4)A . The Engineer is not responsible for delays due to problems in getting the plant certified.

6-02.3(4)A Qualification of Concrete Suppliers

Batch Plant Prequalification requires a certification by the National Ready Mix Concrete Association (NRMCA). Information concerning NRMCA certification may be obtained from the NRMCA at 900 Spring Street, Silver Springs, MD 20910 or online at www. nrmca.org . The NRMCA certification shall be valid for a 2-year period from the date of certificate. The following documentation shall be submitted to the Engineer; a copy of the current NRMCA Certificate of Conformance, the concrete mix design(s) (WSDOT Form 350-040 ), along with copies of the truck list, batch plant scale certification, admixture dispensing certification, and volumetric water batching devices (including water meters) verification. For central-mixed concrete, the mixer shall be equipped with a timer that prevents the batch from discharging until the batch has been mixed for the prescribed mixing time. A mixing time of 1 minute will be required after all materials and water have been introduced into the drum. Shorter mixing time may be allowed if the mixer performance is tested in accordance with (AASHTO M157 Annex A1 Concrete Uniformity Requirements). Tests shall be conducted by an independent testing lab or by a commercial concrete producer’s lab. If the tests are performed by a producer’s lab, the Engineer or a representative will witness all testing. For shrink-mixed concrete, the mixing time in the stationary mixer shall not be less than 30 seconds or until the ingredients have been thoroughly blended. For transit-mixed or shrink-mixed concrete, the mixing time in the transit mixer shall be a minimum of 70 revolutions at the mixing speed designated by the manufacturer of the mixer. Following mixing, the concrete in the transit mixer may be agitated at the manufacturer’s designated agitation speed. A maximum of 320 revolutions (total of mixing and agitation) will be permitted prior to discharge. All transit-mixers shall be equipped with an operational revolution counter and a functional device for measurement of water added. All mixing drums shall be free of concrete buildup and the mixing blades shall meet the minimum Specifications of the drum manufacturer. A copy of the manufacturer’s blade dimensions and configuration shall be on file at the concrete producer’s office. A clearly visible metal data plate (or plates) attached to each mixer and agitator shall display: (1) the maximum concrete capacity of the drum or container for mixing and agitating, and (2) the rotation speed of the drum or blades for both the agitation and mixing speeds. Mixers and agitators shall always operate within the capacity and speed-of-rotation limits set by the manufacturer. Mixers, when fully loaded, shall keep the concrete uniformly mixed. All mixers and agitators shall be capable of discharging the concrete at a steady rate. Only those transit- mixers which meet the above requirements will be allowed to deliver concrete to a Contracting Agency project covered by these Specifications. In transit-mixing, mixing shall begin within 30 seconds after the cement is added to the aggregates. Central-mixed concrete, transported by truck mixer/agitator, shall not undergo more than 250 revolutions of the drum or blades before beginning discharging. To remain below this limit, the suppler may agitate the concrete intermittently within the prescribed time limit. When water or admixtures are added after the load is initially mixed, an additional 30 revolutions will be required at the recommended mixing speed. For each project, at least biannually, or as required, the Plant Manager will examine mixers and agitators to check for buildup of hardened concrete or worn blades. If this Page 6-14 M 41-10

6-02 Concrete Structuresexamination reveals a problem, or if the Engineer wishes to test the quality of the

concrete, slump tests may be performed with samples taken at approximately the ¼ and ¾ points as the batch is discharged. The maximum allowable slump difference shall be as follows: If the average of the two slump tests is < 4 inches, the difference shall be < 1 inch or if the average of the two slump tests is >4 inches, the difference shall be < 1½ inches. If the slump difference exceeds these limits, the equipment shall not be used until the faulty condition is corrected. However, the equipment may continue in use if longer mixing times or smaller loads produce batches that pass the slump uniformity tests. All concrete production facilities will be subject to verification inspections at the discretion of the Engineer. Verification inspections are a check for: current scale certifications; accuracy of water metering devices; accuracy of the batching process; and verification of coarse aggregate quality. If the concrete producer fails to pass the verification inspection, the following actions will be taken:

6-02.3(4)B Jobsite Mixing

For small quantities of concrete, the Contractor may mix concrete on the job site provided the Contractor has requested in writing and received written permission from the Engineer. The Contractor’s written request shall include a mix design, batching and mixing procedures, and a list of the equipment performing the job-site mixing. All job site mixed concrete shall be mixed in a mechanical mixer. If the Engineer permits, hand mixing of concrete will be permitted for pipe collars, pipe plugs, fence posts, or other items receiving the concurrence of the Engineer, provided the hand mixing is done on a watertight platform in a way that distributes materials evenly throughout the mass. Mixing shall continue long enough to produce a uniform mixture. No hand mixed batch shall exceed ½ cubic yard. Concrete mixed at the jobsite is never permitted for placement in water.

6-02.3(4)C Consistency

The maximum slump for concrete shall be:

6-02.3(4)D Temperature and Time For Placement

Concrete temperatures shall remain between 55°F and 90°F while it is being placed, except that Class 4000D concrete temperatures shall remain between 55°F and 75°F during placement. The upper limit for placement for Class 4000D concrete may be increased to a maximum of 80°F if allowed by the Engineer. Precast concrete that is heat cured in accordance with Section 6-02.3(25)D shall remain between 50°F and 90°F while being placed. The batch of concrete shall be discharged at the project site no more than 1½ hours after the cement is added to the concrete mixture. The time to discharge may be extended to 1¾ hours if the temperature of the concrete being placed is less than 75°F. With the concurrence of the Engineer and as long as the temperature of the concrete being placed is below 75°F, the maximum time to discharge may be extended to 2 hours. When conditions are such that the concrete may experience an accelerated initial set, the Engineer may require a shorter time to discharge. The time to discharge may be extended upon written request from the Contractor. This time extension will be considered on a case by case basis and requires the use of specific retardation admixtures and the concurrence of the Engineer.

6-02.3(5) Acceptance of Concrete

6-02.3(5)A General

Concrete for the following applications will be accepted based on a Certificate of Compliance to be provided by the supplier as described in Section 6-02.3(5)B :

6-02 Concrete StructuresA sublot is defined as the material represented by an individual strength test. An individual

strength test is the average compressive strength of cylinders from the same sample of material. Each sublot will be deemed to have met the specified compressive strength requirement when both of the following conditions are met:

6-02.3(5)C Conformance to Mix Design

Cement, coarse and fine aggregate weights shall be within the following tolerances of the mix design: Batch Volumes less than or equal to 4 cubic yards Batch Volumes more than 4 cubic yards Cement +5% -1% Cement +5% -1% Aggregate +10% -2% Aggregate +2% -2% If the total cementitious material weight is made up of different components, these component weights shall be within the following tolerances:

6-02 Concrete Structures6-02.3(5)D Test Methods

Acceptance testing will be performed by the Contracting Agency in accordance with the WSDOT Materials Manual M 46-01. The test methods to be used with this Specification are: AASHTO T 22 Compressive Strength of Cylindrical Concrete Specimens FOP for AASHTO R 100 Making and Curing Concrete Test Specimens in the Field FOP for AASHTO T 119 Slump of Hydraulic Cement Concrete FOP for WAQTC TM 2 Sampling Freshly Mixed Concrete FOP for AASHTO T 152 Air Content of Freshly Mixed Concrete by the Pressure Method FOP for AASHTO T 231 Capping Cylindrical Concrete Specimens FOP for AASHTO T 309 Temperature of Freshly Mixed Portland Cement Concrete ASTM C1611 Standard Test Method for Slump Flow of Self-Consolidating Concrete (Inverted Mold Method only) ASTM C1621 Standard Test Method for Passing Ability of Self-Consolidating Concrete by J-Ring (Inverted Mold Method only)

6-02.3(5)E Point of Acceptance

Determination of concrete properties for acceptance will be made based on samples taken as follows: Bridge decks, overlays, bridge approach slabs, and barriers at the discharge of the placement system. All other placements at the truck discharge. It shall be the Contractor’s responsibility to provide adequate and representative samples of the fresh concrete to a location designated by the Engineer for the testing of concrete properties and making of cylinder specimens. Samples shall be provided as directed in Sections 1-06.1 and 1-06.2 . Once the Contractor has turned over the concrete for acceptance testing, no more mix adjustment will be allowed. The concrete will either be accepted or rejected.

6-02.3(5)F Water/Cement Ratio Conformance

The actual water cement ratio shall be determined from the certified proportions of the mix, adjusting for on the job additions. No water may be added after acceptance testing or after placement has begun, except for concrete used in slip forming. For slip-formed concrete, water may be added during placement but shall not exceed the maximum water cement ratio in the mix design, and shall meet the requirements for consistency as described in Section 6-02.3(4)C . If water is added, an air and temperature test shall be taken prior to resuming placement to ensure that Specification conformance has been maintained.

6-02.3(5)G Sampling and Testing for Temperature, Consistency, and Air Content

Concrete properties shall be determined from concrete as delivered to the project and as accepted by the Contractor for placement. The Contracting Agency will perform acceptance testing on all concrete for temperature and air content, if applicable. Concrete that is not self-consolidating concrete will be tested for slump. The following additional acceptance tests will be performed on self-consolidating concrete: M 41-10 Page 6-19 Concrete Structures 6-021. Slump flow within the target slump flow range.

6-02.3(5)H Sampling and Testing for Compressive Strength and Initial Curing

Acceptance testing for compressive strength shall be conducted at the same frequency as the acceptance tests for temperature, consistency, and air content. The Contractor shall provide and maintain a sufficient number of cure boxes in accordance with FOP for AASHTO R 100 for curing concrete cylinders. The cure boxes shall be readily accessible and no more than 500 feet from the point of acceptance testing, unless otherwise allowed by the Engineer. The Contractor shall also provide, maintain and operate all necessary power sources and connections needed to operate the cure boxes. The cure boxes shall be in-place and functioning at the specified temperature for curing cylinders prior to concrete placement. Concrete cylinders shall be cured in the cure boxes in accordance with FOP for AASHTO R 100. The cure boxes shall have working locks and the Contractor shall provide the Engineer with one key to each of the locks. Once concrete cylinders are placed in the cure box, the cure box shall not be disturbed until the cylinders have been removed. The Contractor shall retain the cure box Temperature Measuring Device log and provide it to the Engineer upon request. The Contractor shall protect concrete cylinders in cure boxes from excessive vibration and shock waves during the curing period in accordance with Section 6-02.3(6)D . All cure box costs shall be incidental to the associated item of work.

6-02.3(5)I Test Section for Cast-In-Place SCC

Unless otherwise approved by the Engineer, the Contractor shall construct a test section of the element being constructed of cast-in-place SCC. The Contractor shall confirm, through the SCC placement operation in the test section, the SCC flows the distance required, completely filling the forms and encapsulating the reinforcement as required without leaving voids and pockets and causing segregation of the SCC mix. The test section forms, reinforcing steel and concrete placing operations shall be identical to those to be used in the production elements. Page 6-20 M 41-10

6-02 Concrete StructuresFor horizontal elements, the test section shall simulate the flow of concrete for the

maximum distance anticipated during production concrete placement. The depth and width of the test section for horizontal element may be smaller than the actual depth and width of the element to be cast. For vertical elements, the test section shall be a minimum of 33-percent of the height of the tallest element to be constructed. The Contractor shall submit Type 2 Working Drawings consisting of formwork and reinforcement details of the test section and SCC placement procedures. After removing the forms, the test section will be inspected for signs of honeycombs, cracks, aggregate segregation, sedimentation, cold joints, and other surface and concrete placement defects. If such defects are present, the Contractor shall revise the formwork and SCC placement procedures as necessary to eliminate such defects. Acceptance of the test section and the SCC mix design is contingent on acceptable visual inspection, and a minimum of two 4-inch minimum diameter core samples taken from the placement location and the furthest-most limits of the concrete as identified by the Engineer. The number of core locations will be specified by the Engineer. The difference in average unit weight of the locations represented by the core samples shall be less than 5-percent. The Contractor shall use the same SCC placement procedures confirmed by the Engineer accepted test section for casting the production members.

6-02.3(5)J SCC in Precast Units

SCC for concrete barrier will be accepted in accordance with temperature, air, and compressive strength testing listed in Section 6-02.3(9) . SCC for precast junction boxes, cable vaults, and pull boxes will be accepted in accordance with the temperature and compressive strength testing listed in Section 6-02.3(9) . SCC for precast drainage structure elements will be accepted in accordance with the requirements of AASHTO M199.

6-02.3(5)K Rejecting Concrete

Rejection Without Testing – The Engineer, prior to sampling, may reject any batch or load of concrete that appears defective in composition; such as cement content or aggregate proportions. Rejected material shall not be incorporated in the Structure.

6-02.3(5)L Concrete With Non-Conforming Strength

Concrete with cylinder compressive strengths (fc) that fail to meet acceptance level requirements shall be evaluated for structural adequacy. If the material is found to be adequate, payment shall be adjusted in accordance with the following formula: Pay adjustment = 2(f’c – fc)(UP)(Q) f’cWhere: f’c = Specified minimum compressive strength at 28 days. fc = Compressive strength at 28 days as determined by AASHTO Test Methods. UP = Unit Contract price per cubic yard for the class of concrete involved. Q = Quantity of concrete represented by an acceptance test based on the required frequency of testing. M 41-10 Page 6-21 Concrete Structures 6-02Concrete that fails to meet minimum acceptance levels using the coring method will be evaluated for structural adequacy. If the material is found to be adequate, payment shall be adjusted in accordance with the following formula: Pay adjustment = 3.56(.85f’c – f cores)(UP)(Q) f’cWhere: f’c = Specified minimum compressive strength at 28 days. f cores = Compressive strength of the cores as determined by AASHTO T 22. UP = Unit Contract price per cubic yard for the class of concrete involved. Q = Quantity of concrete represented by an acceptance test based on the required frequency of testing. Where these Specifications designate payment for the concrete on other than a per cubic yard basis, the unit Contract price of concrete shall be taken as $300 per cubic yard for concrete Class 4000, 5000, and 6000. For concrete Class 3000, the unit contract price for Concrete shall be $160 per cubic yard.

6-02.3(6) Placing Concrete

The Contractor shall not place concrete:

6-02 Concrete StructuresTo prevent aggregates from separating, the conveyor belt used to transport concrete shall

not exceed 300 feet in length. If the mix needs protection from sun or rain, the Contractor shall cover the belt. When concrete pumps are used for placement, a Contractor’s representative shall, prior to use on the first placement of each day, visually inspect the pumps water chamber for water leakage. No pump shall be used that allows free water to flow past the piston. If a concrete pump is used as the placing system, the pump priming slurry shall be discarded before placement. Initial acceptance testing may be delayed until the pump priming slurry has been eliminated from the concrete being pumped. Eliminating the priming slurry from the concrete may require that several cubic yards of concrete are discharged through the pumping system and discarded. Use of a concrete pump requires a reserve pump (or other backup equipment) at the site. If the concrete will drop more than 5 feet, it shall be deposited through a sheet metal (or other accepted) conduit. If the form slopes, the concrete shall be lowered through accepted conduit to keep it from sliding down one side of the form. No aluminum conduits or tremies shall be used to pump or place concrete. If aluminum concrete truck end chutes are used, concrete shall be continuously discharged in a manner that minimizes contact time between the concrete and the chute. Before placing bridge deck concrete on steel spans, the Contractor shall release the falsework under the bridge and let the span swing free on its supports. Concrete in flat slab bridges shall be placed in one continuous operation for each span or series of continuous spans. Concrete for bridge decks and the stems of T-beams or box-girders shall be placed in separate operations if the stem of the beam or girder is more than 3 feet deep. First the beam or girder stem shall be filled to the bottom of the slab fillets. Bridge deck concrete shall not be placed until enough time has passed to permit the earlier concrete to shrink (at least 12 hours). If stem depth is 3 feet or less, the Contractor may place concrete in 1 continuous operation if the Engineer concurs. Between expansion or construction joints, concrete in beams, girders, bridge decks, piers, columns, walls, and traffic and pedestrian barriers shall be placed in a continuous operation. After the concrete has been consolidated and prior to the application of cure, all surfaces of concrete that are not placed against forms shall be struck off to the planned elevation or slope and the surface shall be finished by floating with a float to seal the surface. No traffic or pedestrian barrier shall be placed until after the bridge deck is complete for the entire Structure. No concrete barriers shall be placed until the falsework has been released and the span supports itself. The Contractor may choose not to release the deck overhang falsework prior to the barrier placement. The Contractor shall submit a Type 2E Working Drawing consisting of calculations indicating the loads induced into the girder webs due to the barrier weight and all live loads placed on the Structure do not exceed the design capacity of the girder component. This analysis is not required for bridges with concrete Superstructures. No barrier, curb, or sidewalk shall be placed on steel or prestressed concrete girder bridges until the bridge deck reaches a compressive strength of at least 3,000 psi. The Contractor may construct traffic and pedestrian barriers by the slipform method. However, the barrier may not deviate more than ¼ inch when measured by a 10-foot straightedge held longitudinally on the front face, back face, and top surface. Electrical conduit within the barrier shall be constructed in accordance with the requirements of Section 8-20.3(5) . When placing concrete in arch rings, the Contractor shall ensure that the load on the falsework remains symmetrical and uniform. M 41-10 Page 6-23 Concrete Structures 6-02Unless otherwise allowed by the Engineer, arch ribs in open spandrel arches shall be placed in sections. Small key sections between large sections shall be filled after the large sections have shrunk.

6-02.3(6)A Weather and Temperature Limits to Protect Concrete

6-02.3(6)A1 Hot Weather Protection

The Contractor shall provide concrete within the specified temperature limits. Cooling of the coarse aggregate piles by sprinkling with water is permitted provided the moisture content is monitored, the mixing water is adjusted for the free water in the aggregate and the coarse aggregate is removed from at least 1 foot above the bottom of the pile. Sprinkling of fine aggregate piles with water is not allowed. Refrigerating mixing water, or replacing all or part of the mixing water with crushed ice is permitted, provided the ice is completely melted by placing time. If air temperature exceeds 90°F, the Contractor shall use water spray or other accepted methods to cool all concrete-contact surfaces to less than 90°F. These surfaces include forms, reinforcing steel, steel beam flanges, and any others that touch the concrete.

6-02.3(6)A2 Cold Weather Protection

Concrete shall be maintained at or above a temperature of 40°F during the first seven days of the Cold Weather Protection Period and at or above a temperature of 35°F during the remainder of the Cold Weather Protection Period. Cold weather protection requirements do not apply to concrete in shafts and piles placed below the ground line. Prior to placing concrete in cold weather, the Contractor shall submit a Type 2 Working Drawing with a written procedure for cold weather concreting. The procedure shall detail how the Contractor will adequately cure the concrete and prevent the concrete temperature from falling below the minimum temperature. Extra protection shall be provided for areas especially vulnerable to freezing (such as exposed top surfaces, corners and edges, thin sections, and concrete placed into steel forms). Concrete placement will only be allowed if the Contractor’s cold weather protection plan has been accepted by the Engineer. Prior to concrete placement, the Contractor shall review the 7-day temperature predictions for the job site from the Western Region Headquarters of the National Weather Service ( www.wrh.noaa.gov ). When temperatures below 35°F are predicted, the Contractor shall:

6-02 Concrete Structures6-02.3(6)B Placing Concrete in Foundation Seals

If the Plans require a concrete seal, the Contractor shall place the concrete underwater inside a watertight cofferdam, tube, or caisson. Seal concrete shall be placed in a compact mass in still water. It shall remain undisturbed and in still water until fully set. While seal concrete is being deposited, the water elevation inside and outside the cofferdam shall remain equal to prevent any flow through the seal in either direction. The cofferdam shall be vented at the vent elevation shown in the Plans. The thickness of the seal is based upon this vent elevation. The seal shall be at least 18 inches thick unless the Plans show otherwise. The Engineer may change the seal thickness during construction which may require redesign of the footing and the pier shaft or column. Although seal thickness changes may result in the use of more or less concrete, reinforcing steel, and excavation, payment will remain as originally defined in unit Contract prices. To place seal concrete underwater, the Contractor shall use a concrete pump or tremie. The tremie shall have a hopper at the top that empties into a watertight tube at least 10 inches in diameter. The discharge end of the tube on the tremie or concrete pump shall include a device to seal out water while the tube is first filled with concrete. Tube supports shall permit the discharge end to move freely across the entire Work area and to drop rapidly to slow or stop the flow. One tremie may be used to concrete an area up to 18 feet per side. Each additional area of this size requires one additional tremie. Throughout the underwater concrete placement operation, the discharge end of the tube shall remain submerged in the concrete and the tube shall always contain enough concrete to prevent water from entering. The concrete placement shall be continuous until the Work is completed, resulting in a seamless, uniform seal. If the concreting operation is interrupted, the Engineer may require the Contractor to prove by core drilling or other tests that the seal contains no voids or horizontal joints. If testing reveals voids or joints, the Contractor shall repair them or replace the seal at no expense to the Contracting Agency. Concrete Class 4000W shall be used for seals, and it shall meet the consistency requirements of Section 6-02.3(4)C .

6-02.3(6)C Dewatering Concrete Seals and Foundations

After a concrete seal is constructed, the Contractor shall pump the water out of the cofferdam and place the rest of the concrete in the dry. This pumping shall not begin until the seal has set enough to withstand the hydrostatic pressure (3 days for gravity seals and 10 days for seals containing piling or shafts). The Engineer may extend these waiting periods to ensure structural safety or to meet a condition of the operating permit. If weighted cribs are used to resist hydrostatic pressure at the bottom of the seal, the Contractor shall anchor them to the foundation seal. Any method used (such as dowels or keys) shall transfer the entire weight of the crib to the seal. No pumping shall be done during or for 24 hours after concrete placement unless done from a suitable sump separated from the concrete Work by a watertight wall. Pumping shall be done in a way that rules out any chance of concrete being carried away.

6-02.3(6)D Protection Against Vibration

Freshly placed concrete shall not be subjected to excessive vibration and shock waves during the curing period until it has reached a 2,000 psi minimum compressive strength for structural concrete and lower-strength classes of concrete. After the first 5 hours from the time the concrete has been placed and consolidated, the Contractor shall keep all vibration producing operations at a safe horizontal distance from the freshly placed concrete by following either the prescriptive safe distance method or the monitoring safe distance method. These requirements for the protection of freshly M 41-10 Page 6-25 Concrete Structures 6-02placed concrete against vibration shall not apply for plant cast concrete, nor shall they apply to the vibrations caused by the traveling public.

6-02.3(6)D1 Prescriptive Safe Distance Method

After the concrete has been placed and consolidated, the Contractor shall keep all vibration producing operations at a safe horizontal distance from the freshly placed concrete as follows: Minimum Compressive Strength, f’cSafe Horizontal Distance1 Equipment Class L2 Equipment Class H3 < 1,000 psi 75 feet 125 feet 1,000 to < 1,400 psi 30 feet 50 feet 1,400 to 2,000 psi 15 feet 25 feet 1The safe horizontal distance shall be reduced to 10 feet for small rubber tire construction equipment like backhoes under 50,000 pounds, concrete placing equipment, and legal Highway vehicles if such equipment travels at speeds of: • ≤ 5 mph on relatively smooth Roadway surfaces or • ≤ 3 mph on rough Roadway surfaces (i.e., with potholes) 2Equipment Class L (Low Vibration) shall include tracked dozers under 85,000 pounds, track vehicles, trucks (unless excluded above), hand-operated jack hammers, cranes, auger drill rig, caisson drilling, vibratory roller compactors under 30,000 pounds, and grab-hammers. 3Equipment Class H (High Vibration) shall include pile drivers, vibratory hammers, machine-operated impact tools, pavement breakers, and other large pieces of equipment. After the concrete has reached a minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply.

6-02.3(6)D2 Monitoring Safe Distance Method

The Contractor may monitor the vibration producing operations in order to decrease the safe horizontal distance requirements of the prescriptive safe distance method. If this method is chosen, all construction operations that produce vibration or shock waves in the vicinity of freshly placed concrete shall be monitored by the Contractor with monitoring equipment sensitive enough to detect a minimum peak particle velocity (PPV) of 0.10 inches per second. Monitoring devices shall be placed on or adjacent to the freshly placed concrete when the measurements are taken. During the time subsequent to the concrete placement, the Contractor shall cease all vibration or shock producing operations in the vicinity of the newly placed concrete when the monitoring equipment detects excessive vibration and shock waves defined as exceeding the following PPVs: Minimum Compressive Strength, f’c Maximum PPV < 1,000 psi 0.10 in/sec 1,000 to < 1,400 psi 1.0 in/sec 1,400 to 2,000 psi 2.0 in/sec After the concrete has reached a minimum compressive strength specified above, the safe horizontal distance restrictions would no longer apply.

6-02.3(7) Tolerances

Unless noted otherwise, concrete construction tolerances shall be in accordance with this section. Tolerances in this section do not apply to cement concrete pavement. Horizontal deviation of roadway crown points, cross-slope break points, and curb, barrier or railing edges from alignment or work line: ±1.0 inch Deviation from plane: ±0.5 inch in 10 feet Page 6-26 M 41-10

6-02 Concrete StructuresDeviation from plane for roadway surfaces: ±0.25 inch in 10 feet

Deviation from plumb or specified batter: ±0.5 inch in 10 feet, but not to exceed a total of ±1.5 inches Plumbness or vertical deviation of webs for precast concrete girders and beams at points of support after erection: ± 1/8 inch in 1 foot Vertical deviation from profile grade for roadway surfaces: ±1 inch Vertical deviation of top surfaces (except roadway surfaces): ±0.75 inch Thickness of bridge decks and other structural slabs not at grade: ±0.25 inch Length, width and thickness of elements such as columns, beams, crossbeams, diaphragms, corbels, piers, abutments and walls, including dimensions to construction joints in initial placements: +0.5 inch, -0.25 inch Length, width and thickness of spread footing foundations: +2 inches, -0.5 inch Horizontal location of the as-placed edge of spread footing foundations: The greater of ±2% of the horizontal dimension of the foundation perpendicular to the edge and ±0.5 inch. However, the tolerance shall not exceed ±2 inches. Location of opening, insert or embedded item at concrete surface: ±0.5 inch Cross-sectional dimensions of opening: ±0.5 inch Bridge deck, bridge approach slab, and bridge traffic barrier expansion joint gaps with a specified temperature range, measured at a stable temperature: ±0.25 inch Horizontal deviation of centerline of bearing pad, oak block or other bearing assembly: ±0.125 inch Horizontal deviation of centerline of supported element from centerline of bearing pad, oak block or other bearing assembly ±0.25 inch Vertical deviation of top of bearing pad, oak block or other bearing assembly: ±0.125 inch

6-02.3(8) Vibration of Concrete

The Contractor shall supply enough vibrators to consolidate the concrete (except that placed underwater) according to the requirements of this section. Each vibrator shall:

6-02.3(9) Precast Concrete Units

Precast concrete units may be cast at a manufacturing facility or cast on-site within the project limits unless otherwise stated in these Specifications. Pretensioned prestressed precast concrete units are prohibited from being cast on-site. The manufacturing facility shall be certified by the Precast/Prestressed Concrete Institute’s Plant Certification Program for the type of precast member to be produced, or the National Precast Concrete Association’s Plant Certification Program or be an International Congress Building Officials or International Code Council Evaluation Services recognized fabricator of structural precast concrete products, and shall be approved by WSDOT as a Certified Precast Concrete Fabricator prior to the start of production. WSDOT Certification will be granted at, and renewed during, the annual precast plant review and approval process in accordance with WSDOT Materials Manual M 46-01 Standard Practice QC 7. Products that require annual plant approval include noise barrier panels, wall panels, floor and roof panels, marine pier deck panels, retaining walls, pier caps, and bridge deck panels. Precast concrete panels that are prestressed shall meet all the requirements of Section 6-02.3(25) . Precast units that are cast within the project limits shall be considered cast on-site and are exempt from the fabrication plant approval requirement for precast products. Cast on-site units shall meet all the same quality control standards as a manufacturing facility, and all the requirements in these Specifications. Additionally, the Contractor shall submit a Type 2E Working Drawing consisting of an On-site Pre-casting and Quality Control Plan for review prior to beginning any on-site precast work. This may be a Type 2 Working Drawing if item 6 does not apply. The On-site Pre-casting and Quality Control Plan shall include at a minimum the following items:

6-02 Concrete StructuresThe Contractor shall be responsible for quality control inspection on all precast concrete

units. Prior to the start of production of the precast concrete units, the Contractor shall advise the Engineer of the production schedule. The Contractor shall give the Inspector safe and free access to the Work. If the Inspector observes non-specification Work or unacceptable quality control practices, the Inspector will advise the plant manager if cast at a manufacturing facility or the Contactor’s Quality Control Supervisor if cast on-site. If the corrective action is not acceptable to the Engineer, the units will be subject to rejection. Type III portland cement or blended hydraulic cement is permitted to be used in precast concrete units. Self-consolidating concrete (SCC) may be used in accordance with Section 6-02.3(2)A . Acceptance testing shall be performed by the Contractor and test results shall be submitted to the Engineer when cast at a manufacturing facility. When cast on site, acceptance testing shall be performed by WSDOT. Concrete shall conform to the requirements specified in Section 6-02.3(2)A and Section 6-02.3(5) , unless otherwise noted. The test methods described in Section 6-02.3(5)D shall be followed, unless otherwise noted. Compressive strength testing shall be performed a minimum of once per day and once for every 20 cubic yards of concrete that is placed.

6-02.3(9)A Shop Drawings

Before casting the structural elements, the Contractor shall submit Type 2 Working Drawings of the precast unit shop drawings. These shop drawings shall show complete details of the methods, materials, and equipment the Contractor proposes to use in prestressing/precasting Work. The shop drawings shall follow the design conditions shown in the Plans and accepted On-site Pre-casting Quality Control Plan, if applicable, unless the Engineer concurs with equally effective variations. The shop drawings shall contain as a minimum:

6-02.3(9)B Casting

Before casting precast concrete units, the Contractor and Fabrication Inspector or Engineer shall have possession of a processed set of shop drawings. Concrete shall meet the requirements of Section 6-02.3(25)C for annual preapproval of the concrete mix design and slump. Concrete for cast on-site units shall be in accordance with the accepted On-site Pre-casting and Quality Control Plan. Precast units shall not be removed from forms until the concrete has attained a minimum compressive strength of 70 percent of the specified design strength. A minimum compressive strength less than 70 M 41-10 Page 6-29 Concrete Structures 6-02percent may be used for specific precast units if calculations are submitted and accepted in a Type 2E Working Drawing computed in accordance with the PCI Design Handbook indicating the required compressive strength for product handling. The calculations shall include, at a minimum, the effects of stripping, rigging configuration, stripping method, form suction, impact factors, effects of bunking, and the recommended safety factor for the modulus of rupture. Curing requirements of Section 6-02.3(9)C shall be maintained until 70% of the specified design strength is achieved. Forms may be steel or plywood faced, providing they impart the required finish to the concrete.

6-02.3(9)C Curing

Concrete in the precast units shall be cured by either moist or accelerated curing methods. The curing methods to be used by a manufacturing facility shall be preapproved in the WSDOT plant certification process. The methods to be used when cast on-site shall be as accepted in the On-site Pre-casting and Quality Control Plan.

6-02.3(9)D Control Strength

The concrete strength at stripping and the verification of design strength shall be determined by testing cylinders made from the same concrete as the precast units. The cylinders shall be made, handled, and stored in accordance with WSDOT FOP for AASHTO R 100 and compression tested in accordance with AASHTO T 22 and AASHTO T 231. For accelerated cured units, concrete strength shall be measured on test cylinders cast from the same concrete as that in the unit. These cylinders shall be cured under time- temperature relationships and conditions that simulate those of the unit. If the forms are heated by steam or hot air, test cylinders will remain in the coolest zone throughout curing. If forms are heated another way, the Contractor shall provide a record of the curing time- temperature relationship for the cylinders for each unit to the Engineer. When two or more units are cast in a continuous line and in a continuous operation, a Page 6-30 M 41-10

6-02 Concrete Structuressingle set of test cylinders may represent all units provided the Contractor demonstrates

uniformity of casting and curing to the satisfaction of the Engineer. The Contractor shall mold, cure, and test enough of these cylinders to satisfy Specification requirements for measuring concrete strength. The Contractor may use 4- by 8-inch or 6- by 12-inch cylinders. The Contractor shall let cylinders cool for at least ½ hour before testing for release strength. Test cylinders may be cured in a moist room or water tank, unless otherwise specified in the Contract, in accordance with FOP for AASHTO R 100 after the unit concrete has obtained the required release strength. If, however, the Contractor intends to ship or transport the unit, when cast on-site, prior to standard 28-day strength test, the design strength for shipping shall be determined from cylinders placed with the unit and cured under the same conditions as the unit. These cylinders may be placed in a non-insulated, moisture-proof envelope. To measure concrete strength in the precast unit, the Contractor shall randomly select two test cylinders and average their compressive strengths. The compressive strength in each cylinder shall not fall more than 5 percent below the specified strength. If these two cylinders do not pass the test, two other cylinders shall be selected and tested.

6-02.3(9)E Finishing

The Contractor shall provide a finish on all relevant concrete surfaces as defined in Section 6-02.3(14) , unless the Plans or Special Provisions require otherwise.

6-02.3(9)F Tolerances

The precast units shall be fabricated as shown in the Plans, and shall meet the dimensional tolerances listed in the latest edition of PCI-MNL-116, unless otherwise required by the Specifications, Plans or Special Provisions.

6-02.3(9)G Handling and Storage

The Contractor shall lift all units only by adequate devices at locations designated on the shop drawings. The precast units shall not be stored or handled in a manner such that the stresses imposed on the structure, as presented in the On-site Pre-casting and Quality management Plan, are exceeded or cause damage to the structure including cracking and spalling. The Contactor shall submit lifting calculations as a supplement to the On-Site Pre-Casting Quality Control Plan at the request of the Engineer. Precast units shall be stored off the ground on foundations suitable to prevent differential settlement or twisting of the unit. Stacked units shall be separated and supported by dunnage of uniform thickness capable of supporting the unit. Dunnage shall be arranged in vertical planes. The upper units of a stacked tier shall not be used as storage areas for shorter units unless submitted as a Type 2E Working Drawing containing engineering analysis and accepted by the Engineer. Precast units with hairline cracks visibly apparent, radiating from the lifting loops or support locations extending more than three inches along the structure, or with hairline cracks in other locations, will be subject to evaluation by the Engineer for possible rejection. Precast units whose lifting loops pull out will be subject to evaluation by the Engineer for possible rejection.

6-02.3(9)H Shipping

Precast units shall not be shipped or transported if cast on-site until the concrete has reached the specified design strength, and the Engineer has reviewed the fabrication documentation for Contract compliance. Units cast at a manufacturing facility shall be stamped “Approved for Shipment”. Units cast on site shall not be transported to their permanent location until approved by the Engineer. The units shall be supported in such a manner that they will not be damaged by anticipated impact on their dead load. Sufficient M 41-10 Page 6-31 Concrete Structures 6-02padding material shall be provided between tie chains and cables to prevent chipping or spalling of the concrete.

6-02.3(9)I Erection

Precast units shall not be erected until the concrete has reached the specified design strength, and the Engineer has reviewed the fabrication documentation for Contract compliance. When the precast units arrive on the project from the manufacturing facility, the Engineer will confirm that they are stamped “Approved for Shipment”. The Engineer will evaluate the present units for damage before accepting them. Units cast on-site shall be inspected and approved by the Engineer prior to erection. The Contractor shall lift all precast units by suitable devices at locations designated on the shop drawings. Temporary shoring or bracing shall be provided, if necessary. Precast units shall be properly aligned and leveled as required by the Plans. Variations between adjacent elements shall be leveled out by a method accepted by the Engineer.

6-02.3(10) Bridge Decks and Bridge Approach Slabs

6-02.3(10)A Pre-Deck Pour Meeting

A pre-deck pour meeting shall be held 5 to 10 working days before placing deck concrete to discuss construction procedures, personnel, equipment to be used, concrete sampling and testing and deck finishing and curing operations. Those attending shall include, at a minimum, the superintendent, foremen in charge of placing and finishing concrete, and representatives from the concrete supplier and the concrete pump truck supplier. If the project includes more than one bridge deck, and if the Contractor’s key personnel change between concreting operations, or at request of the Engineer, additional conferences shall be held before each deck placement.

6-02.3(10)B Screed Rail Supports

The Contractor shall place screed rails outside the finishing area. When screed rails cannot be placed outside the finishing area as determined by the Engineer, they shall rest on adjustable supports that can be removed with the least possible disturbance to the screeded concrete. The supports shall rest on structural members or on forms rigid enough to resist deflection. Supports shall be removable to at least 2 inches below the finished surface. For staged constructed bridge decks, the finishing machine screed rails shall not be supported on the completed portion of deck and shall deflect with the portion of structure under construction. Screed rails (with their supports) shall be strong enough and stiff enough to permit the finishing machine to operate effectively on them. All screed rails shall be placed and secured for the full length of the deck/slab before the concreting begins. If the Engineer concurs in advance, the Contractor may move rails ahead onto previously set supports while concreting progresses. However, such movable rails and their supports shall not change the set elevation of the screed. On steel truss and girder spans, screed rails and bulkheads may be placed directly on transverse steel floorbeams, with the strike-board moving at right angles to the centerline of the Roadway.

6-02.3(10)C Finishing Equipment

The finishing machine shall be self-propelled and be capable of forward and reverse movement under positive control. The finishing machine shall be equipped with augers and a rotating cylindrical single or double drum screed. The finishing machine shall have the necessary adjustments to produce the required cross section, line, and grade. The finishing machine shall be capable of raising the screeds, augers, and any other parts of the finishing mechanical operation to clear the screeded surface and returning to the specified grade under positive control. Unless otherwise allowed by the Engineer, a Page 6-32 M 41-10

6-02 Concrete Structuresfinishing machine manufacturer technical representative shall be on site to assist the first

use of the machine on the Contract. For bridge deck widening of 20 feet or less, and for bridge approach slabs, or where jobsite conditions do not allow the use of the conventional configuration finishing machines, or modified conventional machines as described above, the Contractor may submit a Type 2 Working Drawing proposing the use of a hand-operated motorized power screed such as a “Texas” or “Bunyan” screed. This screed shall be capable of finishing the bridge deck and bridge approach slab to the same standards as the finishing machine. On bridge decks, the Contractor may use hand-operated strike-boards only when the Engineer concurs for special conditions where self-propelled or motorized hand-operated screeds cannot be employed. These boards shall be sturdy and able to strike off the full placement width without intermediate supports. Strike-boards, screed rails, and all other specially made auxiliary equipment shall receive the Engineer’s concurrence before use. All finishing requirements in these Specifications apply to hand-operated finishing equipment.

6-02.3(10)D Concrete Placement, Finishing, and Texturing

6-02.3(10)D1 Test Slab Using Bridge Deck Concrete

After the Contractor receives the Engineer’s acceptance of the Class 4000D concrete mix design, and a minimum of seven calendar days prior to the first placement of bridge deck concrete, the Contractor shall construct a test slab using concrete of the accepted mix design. The test slab may be constructed on grade, shall have a minimum thickness of 8-inches, shall have minimum plan dimensions of 10-feet along all four edges, and shall be square or rectangular. During construction of the test slab, the Contractor shall demonstrate concrete sampling and testing, use of the concrete temperature monitoring system, the concrete fogging system, concrete placement system, and the concrete finishing operation. The Contractor shall conduct the demonstration using the same type of equipment to be used for the production bridge decks, except that the Contractor may elect to finish the test slab with a hand-operated strike-board. After the construction of the test slab and the demonstration of bridge deck construction operations is complete, the Contractor shall remove and dispose of the test slab in accordance with Sections 2-02.3 and 2-03.3(7)C .

6-02.3(10)D2 Preparation for Concrete Placement

Before placing bridge approach slab concrete, the subgrade shall be constructed in accordance with Sections 2-06 and 5-05.3(6) . Before concrete is placed, the finishing machine shall be operated over the entire length of the deck/slab to check screed deflection. Concrete placement may begin only if the Engineer accepts after this test. Immediately before placing concrete, the Contractor shall check (and adjust if necessary) all falsework and wedges to minimize settlement and deflection from the added mass of the concrete deck/slab. The Contractor shall also install devices, such as telltales, by which the Engineer can readily measure settlement and deflection.

6-02.3(10)D3 Concrete Placement

The placement operation shall cover the full width of the bridge deck or the full width between construction joints. The Contractor shall locate all construction joints over a beam or web that can support the deck/slab on each side of the joint. The joint shall not occur over a pier unless the Plans permit. Each joint shall be formed vertically and in true alignment. The Contractor shall not release falsework or wedges supporting M 41-10 Page 6-33 Concrete Structures 6-02bridge deck placement sections on either side of a joint until each side has aged as these Specifications require. Placement of concrete for bridge decks and bridge approach slabs shall comply with

6-02 Concrete Structures6-02.3(10)D4 Vacant

6-02.3(10)D5 Bridge Deck Concrete Finishing and Texturing

Except as otherwise specified for portions of bridge decks receiving an overlay or sidewalk under the same Contract, the Contractor shall texture the surface of the bridge deck as follows: The Contractor shall texture the bridge deck using diamond tipped saw blades mounted on a power driven, self-propelled machine that is designed to texture concrete surfaces. The grooving equipment shall provide grooves that are ⅛" ± 1/64" wide, 3/16" ± 1/16" deep, and spaced at ¾" ± ⅛". The bridge deck shall not be textured with a metal tined comb. The Contractor shall submit a Type 2 Working Drawing consisting of the type of grooving equipment to be used. The Contractor shall demonstrate that the method and equipment for texturing the bridge deck will not chip, spall or otherwise damage the deck. Unless otherwise allowed by the Engineer, the Contractor shall texture the concrete bridge deck surface either in a longitudinal direction, parallel with centerline or in a transverse direction, perpendicular with centerline. The Contractor shall texture the bridge deck surface to within 3-inches minimum and 24-inches maximum of the edge of concrete at expansion joints, within 1-foot minimum and 2-feet maximum of the curb line, and within 3-inches minimum and 9-inches maximum of the perimeter of bridge drain assemblies. The Contractor shall contain and collect all concrete dust and debris generated by the bridge deck texturing process, and shall dispose of the collected concrete dust and debris in accordance with Section 2-03.3(7)C . If the Plans call for placement of a sidewalk or an HMA or concrete overlay on the bridge deck, the Contractor shall produce the final finish of these areas by dragging a strip of damp, seamless burlap lengthwise over the bridge deck or by brooming it lightly. Approximately 3-feet of the drag shall contact the surface, with the least possible bow in its leading edge. It shall be kept wet and free of hardened lumps of concrete. When the burlap drag fails to produce the required finish, the Contractor shall replace it. When not in use, it shall be lifted clear of the bridge deck. After the bridge deck has cured, the surface shall conform to the surface smoothness requirements specified in Section 6-02.3(10)D3 . Areas identified as not meeting the requirements of Section 6-02.3(10)D3 shall be repaired with a procedure acceptable to the Engineer. All repairs shall be completed prior to surface texturing. Methods used to remove high spots shall cut through the mortar and aggregate without breaking or dislodging the aggregate or causing spalls.

6-02.3(10)D6 Bridge Approach Slab Finishing and Texturing

Bridge approach slabs that are being built as part of a bridge construction project shall be textured in accordance with Section 6-02.3(10)D5 . All other bridge approach slabs shall be textured using metal tined combs in the transverse direction, except bridge approach slabs receiving an overlay in the same Contract shall be finished as specified in The comb shall be made of a single row of metal tines. It shall leave striations in the fresh concrete approximately 3/16-inch deep by ⅛-inch wide and spaced approximately ½-inch apart. The Engineer will decide actual depths at the site. If the comb has not been accepted, the Contractor shall obtain the Engineer’s acceptance by demonstrating it on a test section. The Contractor may operate the combs manually or mechanically, either M 41-10 Page 6-35 Concrete Structures 6-02singly or with several placed end to end. The timing and method used shall produce the required texture without displacing larger particles of aggregate. Texturing shall end 2-feet from curb lines. This 2-foot untextured strip shall be hand finished with a steel trowel. Surface smoothness, high spots, and low spots shall be addressed as specified in Section

6-02.3(10)D5 The surface texture on an area cut down or built up shall match closely

that of the surrounding bridge approach slab area. The entire bridge approach slab shall provide a smooth riding surface.

6-02.3(10)E Sidewalk

Concrete for sidewalk shall be well compacted, struck off with a strike-board, and floated with a wooden float to achieve a surface that does not vary more than ⅛ inch under a 10- foot straightedge. An edging tool shall be used to finish all sidewalk edges and expansion joints. The final surface shall have a granular texture that will not turn slick when wet.

6-02.3(10)F Bridge Approach Slab Orientation and Anchors

Bridge approach slabs shall be constructed full bridge deck width from outside usable Shoulder to outside usable Shoulder at an elevation to match the Structure. Unless otherwise shown in the Plans, the pavement end of the bridge approach slab shall be constructed normal to the Roadway centerline. The bridge approach slabs shall be modified as shown in the Plans to accommodate the grate inlets at the bridge ends if the grate inlets are required. Bridge approach slab anchors shall be installed as detailed in the Plans, and the anchor rods, couplers, and nuts shall conform to Section 9-06.5(1) . The steel plates shall conform to ASTM A36. All metal parts of the approach expansion anchor shall receive one coat of paint conforming to Section 9-08.1(2)F or be galvanized in accordance with AASHTO M232. The pipe shall be non-perforated PE or PVC pipe of the diameter specified in the Plans. Polystyrene shall conform to Section 9-04.6 . The anchors shall be installed parallel both to profile grade and centerline of Roadway. The Contractor shall secure the anchors to ensure that they will not be misaligned during concrete placement. For Method B anchor installations, the epoxy bonding agent used to install the anchors shall be Type IV conforming to Section 9-26.1 . The compression seal shall be as noted in the Contract documents. Dowel bars shall be installed in the bridge approach slabs in accordance with the requirements of the Standard Plans and Section 5-05.3(10) . The compression seal shall be a 2½ inch wide gland and shall conform to Section 9-04.1(4) .

6-02.3(11) Curing Concrete

After placement, concrete surfaces shall be cured as follows:

6-02 Concrete Structureswater shall be collected and disposed of in accordance with all applicable regulations. In

no case shall runoff water be allowed to enter lakes, streams, or other surface waters. When curing compound is specified, it shall conform to Section 9-23.2 . The Contractor shall use white pigmented curing compound (Type 2), unless stated otherwise. If the surface will be covered with HMA, the curing compound shall be white (Type 2, Class B). For bridge sidewalks, the curing compound shall be clear (Type 1, Class B). The compound shall be applied immediately after finishing and shall be agitated thoroughly just before and during application. Application of the second coat shall run at right angles to that of the first, and the coverage shall total at least 1 gallon per 150 square feet. If any curing compound spills on construction joints or reinforcing steel, the Contractor shall remove it before the next concrete placement. If other materials are to be bonded to the surface (e.g., HMA, pigmented sealer), the Contractor shall remove the curing compound by sandblasting or acceptable high-pressure water washing after the curing is completed. The Contractor shall have on the site, back-up spray equipment, enough workers, and (if needed) a work bridge from which they will apply the curing compound. The Engineer may require the Contractor to demonstrate (at least 1 day before the scheduled concrete placement) that the crew and equipment can apply the compound acceptably. When white, reflective type sheeting is specified, it shall conform to Section 9-23.1 . The sheeting shall be kept in place by taping or weighting the edges where they overlap. When curing bridge approach slabs, two coats of curing compound shall be applied within 15 minutes after floating and tining any portion of the bridge approach slabs. The continuous wet curing shall be established as soon as the concrete has set enough to allow covering without damaging the finish. When accelerating admixtures are used, the concrete shall be cured in accordance with these Specifications or until the concrete has reached 70 percent of the mix design 28-day strength, but not less than 3 days.

6-02.3(11)A Curing and Finishing Concrete Barriers and Rail Bases

6-02.3(11)A1 Fixed-Form Barrier

The fixed-form wet curing period shall be at least 10 days. The edge chamfers shall be formed by attaching chamfer strips to the barrier forms. After troweling and edging a barrier (while the forms remain in place), the Contractor shall:

9-20.4(2) at a ratio of 1:1 cement/aggregate ratio into air holes and small crevices on all

surfaces except the brushed top. As soon as the mortar takes its initial set, the Contractor shall rub it off with a piece of sacking or carpet. The barrier shall then be completely covered with wet blankets for the greater of 48 hours or the remainder of the wet curing period. If the above steps of cleaning and filling with mortar are performed during the 10-day wet curing period, the wet curing blankets shall only be removed in the immediate Work area while the Work is being performed and for no longer than 8 hours. No curing compound shall be used on fixed-form concrete barrier. The completed surface of the concrete shall be even in color and texture.

6-02.3(11)A2 Slip-Form Barrier

The edge radius shall be formed by attaching radius strips to the barrier slip form. The Contractor shall finish slip-form barrier by: (1) steel troweling to close all surface pockmarks and holes; and (2) for plain surface barrier, lightly brushing the front and back face with vertical strokes and the top surface with transverse strokes. After finishing, the Contractor shall cure the slip-form barrier by using either Method A (curing compound) or B (wet blankets) described below. Method A – Under the curing compound method, the Contractor shall:

6-02 Concrete StructuresMethod B – Under the wet curing method, the Contractor shall:

6-02.3(11)B Curing Bridge Deck

6-02.3(11)B1 Equipment & Submittals

The fogging apparatus shall consist of pressure washers with a minimum nozzle output of 1,500 psi, or other means accepted by the Engineer. The Contractor shall submit a Type 2 Working Drawing consisting of the bridge deck curing plan a minimum of 14 calendar days prior to the pre-deck pour meeting. The Contractor’s plan shall describe the sequence and timing that will be used to fog the bridge deck, apply pre-soaked burlap, install soaker hoses and cover the deck with white , reflective sheeting.

6-02.3(11)B2 Curing

The fogging apparatus shall be in place and charged for fogging prior to beginning concrete placement for the bridge deck. The Contractor shall presoak all burlap to be used to cover the deck during curing. Immediately after the finishing machine passes over finished concrete, the Contractor shall implement the following tasks:

6-02.3(12) Construction Joints

6-02.3(12)A Construction Joints in New Construction

If the Engineer allows, the Contractor may add, delete, or relocate construction joints shown in the Plans. All requests for such changes shall be in writing, accompanied by a drawing that depicts them and shall be submitted as an RFI in accordance with Section

1-05.1(2) The Contractor will bear all added costs that result from such changes.

M 41-10 Page 6-39 Concrete Structures 6-02All construction joints shall be formed neatly with grade strips or other accepted methods. The Contracting Agency will not accept irregular or wavy pour lines. All joints shall be horizontal, vertical, or perpendicular to the main reinforcement. The Contractor shall not use an edger on construction joints, and shall remove all lips or edging before making the adjacent pour. If the Plans require a roughened surface on the joint, the Contractor shall strike it off to leave grooves at right angles to the length of the member. Grooves shall be installed using one of the following options:

6-02.3(12)B Construction Joints Between Existing and New Construction

If the Plans or Special Provisions require a roughened surface on the joint, the Contractor shall thoroughly roughen the existing surface to a uniformly distributed ¼-inch minimum amplitude surface profile, with peaks spaced at a maximum of 1 inch. Page 6-40 M 41-10

6-02 Concrete StructuresIf the Plans or Special Provisions do not require a roughened surface on the joint, the

Contractor shall remove all loose particles, dust, dirt, laitance, oil, or film of any sort. Before placing fresh concrete against existing concrete, the Contractor shall thoroughly clean and saturate the existing surface. All loose particles, dust, dirt, laitance, oil, or film of any sort shall be removed. The cleaned surface shall be saturated with water for a minimum of 4 hours before the fresh concrete is placed.

6-02.3(13) Expansion Joints

This section outlines the requirements of specific expansion joints shown in the Plans. The Plans may require other types of joints, seals, or materials than those described here. Joints made of a vulcanized, elastomeric compound (with neoprene as the only polymer) shall be installed with a lubricant adhesive as recommended by the manufacturer. The length of a seal shall match that required in the Plans without splicing or stretching. Open joints shall be formed with a template made of wood, metal, or other suitable material. Insertion and removal of the template shall be done without chipping or breaking the edges or otherwise damaging the concrete. Any part of an expansion joint running parallel to the direction of expansion shall provide a clearance of at least ½ inch (produced by inserting and removing a spacer strip) between the two surfaces. The Contractor shall ensure that the surfaces are precisely parallel to prevent wedging from expansion and contraction. All poured rubber joint sealer (and any required primer) shall conform with Section 9-04.2(2) .

6-02.3(13)A Strip Seal Expansion Joint System

The Contractor shall submit Type 2 Working Drawings consisting of the strip seal expansion joint shop drawings. These plans shall include, at a minimum, the following:

6-02.3(13)B Compression Seal Expansion Joint System

Compression seal glands shall conform to Section 9-04.1(4) and be sized as shown in the Plans. The compression seal expansion joint system shall be installed in accordance with the manufacturer’s written recommendations. The Contractor shall submit a Type 1 Working Drawing consisting of the manufacturer’s written installation procedure and repair procedures if leakage testing fails. After the expansion joint system is installed, a watertightness test shall be performed as follows. The Contractor shall flood each completely installed expansion joint system with water to a minimum depth of three inches for a duration of at least one hour. If leakage is observed, the expansion joint system shall be repaired at no additional expense to the Contracting Agency, as recommended by the manufacturer. After repairs are completed, the expansion joint shall be retested for leakage.

6-02.3(13)C Modular Expansion Joint System

The Contractor shall design, fabricate, inspect, test, and install a modular, multiple seal expansion joint system in accordance with the geometry and movements shown and specified in the Plans. The modular expansion joint system shall extend continuously across the full width of the bridge deck and up into the traffic barriers as shown in the Plans.

6-02.3(13)C1 Acceptable Manufacturers

Only manufacturers whose modular expansion joint systems have met the requirements specified in Section 6-02.3(13)C9 will be permitted to supply modular expansion joint systems. Testing required to establish the fatigue resistance of all details of a specific proprietary system shall be completed prior to the Contract Award date. All fatigue testing shall be conducted in accordance with Sections 6-02.3(13)C11 , 6-02.3(13)C23 , and

6-02.3(13)C26 Testing shall be completed on all revised details or material substitutions

of a previously prequalified system prior to the Contract award date. Manufacturers known to have met the requirements of Section 6-02.3(13)C9 are specified in Section 6-02.3(13)C as supplemented in the Special Provisions. Page 6-42 M 41-10

6-02 Concrete Structures6-02.3(13)C2 Submittals

The expansion joint manufacturer shall have at least three years of experience in designing and manufacturing modular expansion joint systems. The Contractor shall submit a Type 1 Working Drawing consisting of written certification of the manufacturer’s experience, including the location of each bridge, installation date, governmental agency/owner, and the name, address, and telephone number of each owner’s/ agency’s representative. The Contractor shall submit the name of the selected expansion joint system manufacturer to the Engineer within 10 days of Contract award. Once the name of the manufacturer has been submitted to the Engineer, the Contractor shall not select an alternative expansion joint system manufacturer unless the manufacturer demonstrates an inability to meet the requirements of Section 6-02.3(13)C . The Contractor shall submit Type 3E Working Drawings consisting of shop drawings and design calculations delineating the expansion joint system in accordance with Sections

1-05.3 and 6-03.3(7) and as noted herein. The Professional Engineer responsible for

preparing and stamping the submittal shall be an employee of the expansion joint system manufacturer, and shall hold a valid license in the branch of Civil or Structural Engineering, either in the State of Washington or another state. These submittals shall include, at a minimum, the following:

6-02.3(13)C3 General Design Requirements

The expansion joint system shall be designed and detailed with adequate access to all internal components in order to assure the feasibility of inspection and maintenance activities. The expansion joint system shall be designed and detailed to minimize concrete cracking above the support boxes. Measures taken shall include, but not be limited to, assuring adequate support box top plate thickness, specifying any additional bridge deck steel reinforcement required, and providing adequate concrete cover. Page 6-44 M 41-10

6-02 Concrete StructuresThe expansion joint system and bridge deck steel reinforcement shall be detailed to assure

that adequate concrete consolidation can be achieved underneath all support boxes. The expansion joint seals shall not protrude above the top of the expansion joint system under any service condition. Split extrusions may be used at curb upturns. The elastomeric or urethane springs and bearings shall be designed to be removable and replaceable. The removal and reinstallation of each strip seal shall be easily accomplished from above the joint with a 1-1/4 inch minimum gap width. These operations shall be viable with a one lane partial closure of the bridge deck. The expansion joint system shall be designed and detailed to be watertight. The expansion joint system shall be designed and detailed to accommodate all movements specified in the Plans. The expansion joint shall be designed and detailed to mitigate the potential for fatigue damage wherever centerbeam field splices are required. Consideration shall be given to reducing support box spacing and optimizing splice location between adjacent support boxes in order to minimize fatigue stress range at field splices.

6-02.3(13)C4 Design Axle Loads and Impact Factors

The centerbeams, support bars, bearings, connections, and other structural components shall be designed for the simultaneous application of vertical and horizontal loads from a tandem axle. The tandem axle shall consist of a pair of axles spaced four feet apart with vertical and horizontal loads as specified in Section 6-02.3(13)C as supplemented in the Special Provisions. The transverse spacing of the wheels shall be six feet. The distribution of the wheel load among centerbeams shall be as specified in Section 6-02.3(13)C5 .

6-02.3(13)C5 Distribution of Wheel Loads

The following table specifies the centerbeam distribution factor as a function of centerbeam top flange width. This factor is the percentage of the design vertical axle load and the design horizontal axle load that shall be applied to an individual centerbeam for the design of that centerbeam and its associated support bars. Distribution factors shall be interpolated for centerbeam top flange widths between those explicitly denoted in the table. In no case shall the distribution factor be taken as less than 50%. The remainder of the load shall be divided equally and applied to the two adjacent centerbeams or edge beams. Width of Centerbeam Top Flange Distribution Factor 2.5 inches 50% 3.0 inches 60% 4.0 inches 70% 4.75 inches 80%

6-02.3(13)C6 Fatigue Limit State Design Requirements

Modular expansion joint system structural members, bolted and welded splices and connections, and attachments shall be designed to resist the Fatigue Limit State load combination specified in Table 3.4.1-1 of the AASHTO LRFD Bridge Design Specifications. The vertical and horizontal load ranges specified in Section 6-02.3(13)C4 shall be applied simultaneously. These loads shall be distributed as specified in Section 6-02.3(13)C5 . The nominal stress ranges, ∆f, at all fatigue critical details shall be obtained from a structural analysis of the expansion joint system applying the design vertical and horizontal load ranges specified in Section 6-02.3(13)C4 and distributed as specified in Section 6-02.3(13)C5 . The expansion joint system shall be analyzed with a minimum gap opening corresponding to the midrange configuration (at least half of the maximum gap opening). The design axle load shall be applied as two wheel loads, each having a transverse width of 20 inches. M 41-10 Page 6-45 Concrete Structures 6-02For each detail under consideration, the wheel loads shall be positioned transversely on a centerbeam to achieve the maximum nominal stress range at that detail. The vertical and horizontal wheel loads shall be applied as line loads to the top of the centerbeams at their centerlines. The design stress range in the centerbeam-to-support bar connection shall be calculated as specified below. The design nominal stress ranges, ∆f, multiplied by the appropriate load factors in Table 3.4.1-1 of the AASHTO LRFD Bridge Design Specifications, shall be used for fatigue design as specified at the end of this subsection.

6-02.3(13)C7 Welded or Bolted Single-Support-Bar Systems

The nominal stress range, ∆f, in the centerbeam at a welded or bolted stirrup shall be the sum of the longitudinal bending stress ranges at the critical section resulting from vertical and horizontal loading. The effects of stresses in any load-bearing attachments such as the stirrup or yoke shall not be considered when calculating the longitudinal stress range in the centerbeam. For bolted single-support-bar systems, stress ranges shall be calculated using the net section. The nominal stress range, ∆f, in the stirrup or yoke shall be calculated without considering the effects of stresses in the centerbeam. The stress range shall be calculated by assuming a load range in the stirrup equal to 30% of the total vertical reaction force between the centerbeam and the support bar. The effects of horizontal loads may be neglected in the design of the stirrup.

6-02.3(13)C8 Welded Multiple-Support-Bar Systems

Three locations have been identified as initiation sites for fatigue cracking at a centerbeam-to-support bar welded connection. The types of cracking associated with these three locations are described below. The corresponding equations may be used to calculate the nominal stress range, ∆f. For the support bar, either the reduced moment at the critical cross section or the moment at the centerline of the connection may be used in these equations. Centerbeam weld toe cracking is driven by a combination of longitudinal bending stress range, SRB, in the centerbeam, and vertical stress range, SRZ, at the top of the connection weld. The longitudinal bending stress range, SRB, at the bottom of the centerbeam shall be calculated as: SRB = MVcb / SXcb + MHcb / SYcb The vertical stress range, SRZ, at the top of the connection weld shall be calculated as: SRZ = RH∙ dcb / SWtop + RV / AWtop Support bar weld toe cracking is driven by a combination of longitudinal bending stress range, SRB, in the support bar and vertical stress range, SRZ, at the bottom of the connection weld. The longitudinal bending stress range, SRB, at the top of the support bar shall be calculated as: SRB = MVsb / SXsb + 0.5 ∙ RH ∙ (dcb + hW + 0.5 ∙ dsb) / SXsb The vertical stress range, SRZ, at the bottom of the connection weld shall be calculated as: SRZ = RH ∙ (dcb + hW) / Swbot + RV / AWbot Weld throat cracking is driven by a vertical stress range at the weld throat. Page 6-46 M 41-10

6-02 Concrete StructuresThe vertical stress range, SRZ, at mid-height of the connection weld shall be calculated as:

SRZ = RV / Awmid + RH ∙ (dcb + 0.5 ∙ hW) / SWmid In the above equations: RV = vertical reaction at the connection weld RH = horizontal reaction at the connection weld MVcb = bending moment in the centerbeam due to applied vertical forces MHcb = bending moment in the centerbeam due to applied horizontal forces MVsb = bending moment in the support bar due to applied vertical forces SXcb = section modulus at bottom of the centerbeam about horizontal axis SYcb = section modulus of the centerbeam about vertical axis SXsb = section modulus at top of the support bar about horizontal axis AWtop = area of the weld at the top of the connection AWmid = area of the weld at the middle of the connection AWbot = area of the weld at the bottom of the connection SWtop = section modulus of the weld at the top of the connection SWmid = section modulus of the weld at the middle of the connection SWbot = section modulus of the weld at the bottom of the connection hW = height of the weld dcb = depth of the centerbeam dsb = depth of the support bar The nominal stress range, ∆f, at welded multiple-support-bar connection details shall be calculated for each case above as follows: ∆f = (S2 RB + S2 RZ)1/2 Where: SRB = longitudinal stress range in the centerbeam or support bar, as calculated for each specific case above. SRZ = vertical stress range in the centerbeam-to-support bar connection weld, as calculated for each specific case above. All modular expansion joint system structural members, connections (bolted and welded), splices, and attachments shall satisfy the following: γ∆f = (ΔF)TH Where: γ = the load factor for the Fatigue I Limit State, as stipulated in Table 3.4.1-1 of the AASHTO LRFD Bridge Design Specifications. Δf = the nominal stress range as specified at the beginning of this subsection. (ΔF)TH = constant amplitude fatigue threshold (CAFL) as specified in

6-02.3(13)C9 Fatigue Resistance Characterization Requirements

The fatigue resistance of all details shall be characterized in terms of the detail categories specified in Table 6.6.1.2.5-1 of the AASHTO LRFD Bridge Design Specifications. Many details composing modular expansion joint systems may clearly correspond to specific structural details depicted in Figure 6.6.1.2.3-1 of the AASHTO LRFD Bridge Design Specifications. In these cases, the applicable fatigue categories specified in Table 6.6.1.2.3-1 may be used for design. In cases where the Engineer establishes that a detail does not clearly correspond to a structural detail depicted in Figure 6.6.1.2.3-1, fatigue testing of specimens exhibiting that detail shall be conducted, in accordance with Sections 6-02.3(13)C11 , M 41-10 Page 6-47 Concrete Structures 6-026-02.3(13)C23 , and 6-02.3(13)C26 , to establish the appropriate constant amplitude fatigue limit (CAFL) for that detail.

6-02.3(13)C10 Strength I Limit State Design Requirements

Modular expansion joint system structural steel members, connections (bolted and welded), splices, and attachments shall be designed to resist the Strength I Limit State load combination specified in Table 3.4.1-1 of the AASHTO LRFD Bridge Design Specifications. The vertical and horizontal loads specified in Section

6-02.3(13)C4 shall be applied simultaneously. These loads shall be distributed as specified

in Section 6-02.3(13)C5 .

6-02.3(13)C11 Fatigue Testing of Metallic Structural Components and Connections

This test procedure is acceptable for, and specifically applicable to, establishing the fatigue resistance of the centerbeam-to-support bar connection in modular expansion joint systems. It is applicable to single-support-bar and multiple-support-bar systems having either welded or bolted centerbeam-to-support bar connections. The same methodology may be applied to establish the fatigue resistance of other modular expansion joint metallic structural component details, including centerbeam splices. Each fatigue test generates a discrete datum. Each datum comprises an applied constant amplitude nominal stress range, Sr, and the corresponding number of cycles, N, associated with either a predetermined extent of crack propagation, defined as failure, or with termination of the test, defined as runout. Ten data shall be acquired for each connection detail. All data shall be in the very long life range, corresponding as closely to the constant amplitude fatigue limit (CAFL) as practical. Specifically, the number of cycles, N, associated with each datum, shall be no less than one order of magnitude less than Nmin corresponding to the detail category specific CAFL specified in Section 6-02.3(13)C19 . For example, to characterize a detail as Detail Category C, the tested number of cycles, N, shall exceed 4.4 x 105 for each datum. The constant amplitude nominal stress range shall be calculated at the anticipated initiation location of an incipient crack. Nominal stresses shall be calculated using conventional equations for analyzing bending and axial load. These equations are essentially the same as those used in strength design. The stress concentration effects of a weld, bolt hole, or other local features are not explicitly embodied in the conventional nominal stress equations. The appropriate AASHTO detail category applicable to fatigue design shall be established by comparing acquired test data to fatigue resistance graphs representing the AASHTO detail categories. The constant amplitude fatigue limit (CAFL) applicable to fatigue design corresponds to the AASHTO detail category fatigue resistance graph representing a lower bound of the experimentally acquired data. When testing is conducted exclusively in the infinite life regime and more stringent test data scatter requirements are satisfied, a unique CAFL (different from those CAFL corresponding to specific detail categories specified by AASHTO) may be established for fatigue design. Specimens selected for testing shall be full-scale centerbeam and support bar assemblies or subassemblies representative of those installed in field applications. A subassembly is defined as a specimen having the same physical and geometric properties as an assembly but having a reduced number of centerbeams. Each specimen shall consist of three continuous centerbeam spans over four equally spaced support bars. Centerbeam spans between adjacent support bar centerlines shall be a minimum of 3’-0” and a maximum of 4’-6”. Support bar spans shall be a minimum of 3’-0” and a maximum of 3’-8”. The centerbeam-to-support bar connection being tested shall be located at the midspan of each support bar. Page 6-48 M 41-10

6-02 Concrete StructuresAll welded or bolted attachments used to secure equidistant springs to a support bar,

centerbeam, or stirrup shall be fabricated as an integral part of the specimen. A rigid load path to the test fixture shall be provided to resist any horizontal forces or displacements which would normally be resisted through these attachments in a field installation. All miscellaneous welded or bolted attachments, including welded attachments used to secure the expansion joint strip seals to the centerbeams, shall also be fabricated as integral parts of the specimen. Support bars of subassembly specimens that are components of single-support-bar swivel-joist type modular expansion joint systems shall be oriented perpendicular to the longitudinal axis of the centerbeam. Prior to testing, each specimen shall be visually inspected for defects, loose fasteners or other aberrations which could plausibly affect the tested fatigue resistance. Defects and flaws shall be defined in accordance with the appropriate governing specification (ASTM A6, AWS D1.5, etc.). Data acquired from specimens containing such anomalies shall not be excluded from consideration except as permitted in Section 6-02.3(13)C20 . Observed anomalies shall also be reported with its corresponding data in the tabular format stipulated in Section 6-02.3(13)C22 . Each specimen shall be sufficiently instrumented to measure the static nominal strain range within that specimen for a specific applied load range. Best results can generally be obtained when the applied load range for the static calibration tests does not pass through zero load. Strain measurements shall be made at locations sufficiently distant from local effects, such as weld toes or bolt holes, which could significantly influence acquired test data. As a minimum, eight strain gages shall be installed on the centerbeam top flange in the vicinity of each centerbeam-to-support bar connection. These gages shall be installed in pairs on each side of the connection at distances of one and two times the depth of the centerbeam from the centerline of the connection. Each pair of strain gages shall be located symmetrically about the centerline of the centerbeam. As a minimum, two strain gages shall also be installed on the support bar bottom flange in the vicinity of each centerbeam-to-support bar connection. One of these strain gages shall be installed on each side of the connection at a distance equal to the depth of the support bar from the centerline of the connection. These strain gages shall be installed along the centerline of the support bar.

6-02.3(13)C12 Fatigue Testing Test Fixtures

Test fixtures shall have the capability to adequately support and secure the specimen throughout the duration of the test. The fixture shall be designed and fabricated to such tolerances as required to assure that additional stresses will not be generated in the specimen as a consequence of fixture misalignment. Mismatches resulting from specimen fabrication errors shall be accommodated by shimming or other such means precluding the application of force to the specimen. Typical elastomeric bearings and springs used to transfer vertical loads from the support bars to the support boxes may be replaced with steel bearings in the test fixture. This modification will enable fatigue testing at higher load ranges and different frequencies than those encountered during normal service conditions. Load shall be applied through two 10-inch long patches. Each patch shall typically comprise a steel plate and a hard rubber bearing pad placed in contact with the bottom flange of the centerbeam. Each patch shall be located at midspan of each outer span. In order to assure adequate seating of the specimen to the test fixture, a minimum of 10 kips shall be applied at each patch location. This requirement is waived for tests of single support bar systems conducted using load reversal. Once this load has been applied, all strain measuring devices shall be rebalanced to zero strain while the preload M 41-10 Page 6-49 Concrete Structures 6-02is maintained. An additional load approximately equivalent to the calculated load range shall be applied. Strain ranges shall be measured for the load range from 10 kips to the peak load. Each static calibration test shall be repeated three times while still maintaining a minimum 10 kips load at each load patch. The measured strain ranges from each repetition should vary by no more than 25% from the mean value. If the stress ranges are not repeatable, appropriate modifications shall be made to the test fixture.

6-02.3(13)C13 Static Calibration Test

Prior to fatigue resistance testing, a static calibration test shall be performed in order to validate the structural analysis model. The static calibration test shall be performed after attainment of stress range repeatability as described in Section 6-02.3(13)C12 . The structural analysis model shall be considered validated when calculated strain ranges are within ±25% of the measured strain ranges at every strain gage location. For the purpose of reporting nominal fatigue resistance stress ranges at specific details, stress ranges determined through structural analysis of the model shall be preferred over stress ranges acquired directly from test measurements.

6-02.3(13)C14 Fatigue Test Procedure

A minimum of ten data points shall be required to establish the fatigue resistance of each detail. The centerbeam-to-support bar connection shall be considered as a single detail. Several data points may be obtained from a single specimen by repairing the cracked sections of that specimen and resuming testing. Such repairs shall have minimal effect on the stress ranges at unfailed details still being tested. Data points derived from tests in which a repaired detail cracks again shall be discarded. All data shall be in the very long life range, corresponding as closely to the constant amplitude fatigue limit as practical, but in no case less than 200,000 cycles. Either finite life regime or infinite life regime testing may be conducted. For infinite life regime testing, the number of cycles, N, associated with each of the ten data shall be at least twice the number of cycles, Nmin, designated in the table in Section 6-02.3(13)C19 . Loads shall be applied using hydraulic actuators or other similar loading devices. The magnitude of the vertical load range, ∆Pv, shall be maintained and continuously monitored throughout the duration of the test. Vertical and horizontal load ranges shall be applied to the specimen simultaneously. The horizontal load range shall always be equal to 20% of the vertical load range, ∆Pv. This horizontal-to-vertical load ratio may be maintained by inclining the specimen 11.3 degrees with respect to the horizontal plane and applying load through vertically oriented actuators. For multiple support bar systems, the loading mechanism shall be either exclusively tension or exclusively compression and shall be applied at a constant amplitude at any desired frequency. The applied load range shall be in a direction such that the reaction force between the centerbeam and support bar is always tensile. The load range shall not pass through zero load. Minimum preload shall be maintained throughout the duration of the test. Single support bar systems may be loaded using the same procedures as those for multiple support bar systems. If premature stirrup failure occurs, an applied load range of 70% compression and 30% tension may be used. The load ranges used in the test shall not be so large as to alter the observed failure mode from that which would be observed under service conditions. Under no circumstance shall imposed stress exceed the yield stress of the material in any portion of the specimen. Each specimen shall be tested using at least two different load (stress) ranges. If infinite life regime testing is conducted, the first load range should be chosen so that the applied stress range is just above the postulated CAFL. The load range in the subsequent test shall be decreased if failure resulted and increased if the test resulted in a runout. A Page 6-50 M 41-10

6-02 Concrete Structuressuggested increment in load is such that the stress range is increased or decreased by 2

ksi. The applicable CAFL shall be selected from those CAFL values corresponding to the AASHTO fatigue categories. The selected CAFL is the one just below the lowest stress range that resulted in cracking.

6-02.3(13)C15 Fatigue Test Failure Criteria

Failure in welded centerbeam-to-support bar connection specimens includes the following: Centerbeam weld toe cracking originates at or near the centerbeam weld toe, propagates up into the centerbeam at some angle, and grows back over the connection. These cracks typically grow at an angle of about 45 degrees. A specimen shall be considered as failed due to this type of cracking when the crack has grown on any vertical face a length from the point of origin equal to half of the centerbeam depth. Support bar weld toe cracking originates at or near the support bar weld toe, propagates down into the support bar, and grows back under the connection at some angle, typically about 45 degrees. A specimen shall be considered as failed due to this type of cracking when the crack has grown on any vertical support bar face a length from the point of origin equal to half of the depth of the support bar. Weld throat cracking originates in the weld throat and typically grows in a plane parallel to the longitudinal axis of the support bar at about mid-depth of the weld throat. A specimen shall be considered as failed due to this type of cracking when a complete fracture of the weld throat has occurred. These cracks have been observed to turn down into the support bar, but only after significant growth. In such instances, the criteria for support bar weld toe cracking shall be applied. A welded stirrup connection specimen shall be considered as failed when cracks result in the complete fracture of a stirrup leg or when cracks originating at or near a stirrup weld have grown into any face of the centerbeam a length from the stirrup weld toe equal to half of the centerbeam depth. A bolted centerbeam-to-support bar connection specimen shall be considered as failed when:

6-02.3(13)C16 Alternate Criteria for Termination of a Finite Life Regime Fatigue Test

A test may also be terminated when, for a given stress range, the specimen has survived the number of cycles required to plot the data above either a particular fatigue resistance curve or the maximum permitted in Section 6-02.3(13)C20 . For example, if the applied stress range is 17 ksi and the desired fatigue resistance curve is Category C, then based upon the equation presented in Section 6-02.3(13)C19 , the test may be terminated after application of about 900,000 cycles provided that the specimen has not failed based on the above described criteria.

6-02.3(13)C17 Nominal Stress Range for Welded Centerbeam-to-Support Bar Systems

The nominal stress range for centerbeam weld toe cracking shall be calculated by taking the square root of the sum of the squares of the longitudinal bending stress range in the centerbeam and the vertical stress range at the top of the weld. M 41-10 Page 6-51 Concrete Structures 6-02The nominal stress range for support bar weld toe cracking shall be calculated by taking the square root of the sum of the squares of the longitudinal bending stress range in the support bar and the vertical stress range at the bottom of the weld. The nominal stress range for weld throat cracking shall be the calculated vertical stress range in the throat of the weld. The nominal stress range in the centerbeam at a welded stirrup shall be calculated as the summation of the longitudinal bending stress ranges at the critical section resulting from vertical and horizontal loading. The entire load range shall be used in the calculation, even if the loading is partly in compression. The effects of stresses in the load-bearing attachments such as the stirrup or yoke shall not be considered when calculating the nominal stress range in the centerbeam. The load range in the stirrup itself shall be taken as 30% of the total vertical load range carried through the connection. The effect of horizontal forces may be neglected.

6-02.3(13)C18 Nominal Stress Range for Bolted Centerbeam-to-Support Bar Systems

The nominal stress range in the centerbeam shall be taken as the summation of the longitudinal bending stress ranges in the centerbeam resulting from vertical and horizontal loading. Nominal stress ranges shall be calculated using the net section. The effects of stresses in the stirrup shall not be considered when calculating the nominal stress range in the centerbeam. The nominal load range in the bolt group and the stirrup assembly shall be taken as 30% of the total vertical load range carried through the connection. The effect of horizontal forces may be neglected.

6-02.3(13)C19 Interpretation of Fatigue Test Data

The experimentally acquired data and graphs representing the fatigue resistance of the detail categories delineated in Section 6.6 of the AASHTO LRFD Bridge Design Specifications, shall be juxtaposed on a log-log scale. The equation representing the finite life fatigue resistance of these AASHTO detail categories is: N = A / S3 r,eff Where: N = number of cycles to failure. Sr,eff = nominal effective stress range representing fatigue resistance. A = constant defined in Table 6.6.1.2.5-1 of the AASHTO LRFD Bridge Design Specifications. The minimum number of cycles associated with infinite fatigue life, Nmin, and the corresponding constant amplitude fatigue limit (CAFL) for each AASHTO detail category is designated in the table below. Detail Category Nmin (infinite fatigue life) CAFL(ksi) A 1.8 x 106 cycles 24 B 3.0 x 106 cycles 16 B' 3.5 x 106 cycles 12 C 4.4 x 106 cycles 10 C' 2.5 x 106 cycles 12 D 6.4 x 106 cycles 7.0 E 1.2 x 107 cycles 4.5 E' 2.2 x 107 cycles 2.6 Page 6-52 M 41-10

6-02 Concrete Structures6-02.3(13)C20 Finite Life Regime Testing

The number of cycles, N, to either failure or runout, associated with each of the ten data need not exceed Nmin, designated in the table in Section 6-02.3(13)C19 . The detail category applicable to fatigue design shall be that corresponding to the highest of the AASHTO detail category fatigue resistance graphs representing a lower bound of all ten experimentally acquired data. If all but one datum falls above a selected AASHTO S-N curve, that one datum may be discarded and replaced by three new data obtained through additional testing. The additional testing shall be conducted using the same stress range as that of the discarded datum. The three additional data shall be plotted along with the remaining nine data. The applicable detail category shall be that corresponding to the highest of the AASHTO detail category fatigue resistance graphs representing a lower bound of all twelve data, except as limited in the previous table. For any detail, only one datum may be discarded and subsequently replaced with three additional data for any set of ten original data. The maximum fatigue resistance of any detail shall not exceed that associated with the fatigue category prescribed in the table below. Type of DetailMaximum Permitted Category Welded Multiple Centerbeam-to-Support Bar Connections C Weld Stirrup Attachments for Single Support Bar Systems B Bolted Stirrup Attachments for Single Support Bar Systems D Groove Welded Centerbeam Splices1 C Miscellaneous Welded Connections2C Miscellaneous Bolted Connections D 1Groove welded full penetration splices may be increased to Category B if weld integrity is verified using non-destructive testing (NDT). 2Miscellaneous connections include attachments for equidistant devices. The fatigue resistance for stirrups welded to a centerbeam flange shall not be taken greater than that defined using the fatigue details defined in Section 6.6 of the AASHTO LRFD Bridge Design Specifications. The applicable fatigue detail for the centerbeam flange and for the stirrup shall be either a “Longitudinally Loaded Groove-Welded Attachment” or a “Longitudinally Loaded Fillet-Welded Attachment”, depending upon the type of connection used.

6-02.3(13)C21 Infinite Life Regime Testing

The applicable constant amplitude fatigue limit (CAFL) for fatigue design may be selected as the highest CAFL of the AASHTO detail categories representing a lower bound to the experimentally acquired data. The CAFL of the AASHTO detail categories are designated in the table in Section 6-02.3(13)C19 . A unique CAFL (different from the CAFL categories delineated in Section 6.6 of the AASHTO LRFD Bridge Design Specifications) may be established if all ten data are within 4 ksi of that unique CAFL.

6-02.3(13)C22 Data Reporting for Fatigue Tests

Fatigue test results and observations shall be reported in the typical S-N format (logarithm

6-02.3(13)C23 Durability Testing of Elastomeric Support Bearings

This subsection provides guidelines for durability testing of the elastomeric support bearings typically used in modular expansion joint systems as specified In Sections 6-02.3(13)C24 and 6-02.3(13)C25 . It is not applicable to compression springs, equidistant springs, or other elastomeric components. Tests shall be performed dynamically on individual bearings. Fatigue life is evaluated by applying a displacement range to each specimen rather than a load or stress range. Specimens shall comprise full scale bearing components representative of those installed in field applications. PTFE sliding surfaces or materials typically bonded to the elastomeric support bearings shall be fabricated as an integral part of the specimen. Prior to testing, each specimen shall be visually inspected for flaws or defects that could plausibly affect fatigue resistance. All flaws or details shall be defined and recorded. Data obtained from specimens containing such anomalies shall not be excluded from the data set. Observed anomalies shall also be reported with the test data. Test fixtures shall have the capability to adequately support and secure the specimen throughout the duration of the test. The fixture shall be designed and fabricated to such tolerances as required to assure that additional stresses will not be generated in the specimen as a consequence of fixture misalignment. Loads shall be applied through hydraulic actuators or other similar loading devices. Fatigue testing shall be performed using displacement control. Displacement and load ranges shall be continuously monitored throughout the duration of the fatigue test to assure that desired displacement range and minimum preload are maintained. Load shall be applied to the specimen through flat steel plates that are smooth and free of surface corrosion. These plates shall be sufficiently thick to assure even load distribution to the specimen. Page 6-54 M 41-10

6-02 Concrete Structures6-02.3(13)C24 Dynamic Stiffness Test

Testing shall be conducted on each specimen to be subjected to fatigue testing in order to establish its dynamic stiffness for at least three different loading frequencies. The maximum of these loading frequencies shall be equal to the service load frequency corresponding to a vehicle traveling at 60 mph. The loading frequency, f, shall be calculated as: f = 0.5 ∙ V / (g + b) where V = vehicle speed (60 mph at service load) g = centerbeam gap (assume mid-range configuration) b = centerbeam width The load range applied during the dynamic stiffness test shall be that obtained from structural analysis using fatigue wheel load and wheel load distribution factors as specified in Sections 6-02.3(13)C24 and 6-02.3(13)C25 . Each dynamic stiffness test shall be performed three times. Data from individual tests shall be compared to assure consistency of test results.

6-02.3(13)C25 Bearing Fatigue Test

A minimum of three fatigue tests shall be required to establish the durability of each type of bearing. The fatigue test shall be conducted using displacement control. The displacement (strain) range shall be applied using a sine or other smooth waveform at any frequency less than or equal to the service load frequency calculated in Section 6-02.3(13)C24 . The magnitude of the applied displacement amplitude, Δ, shall be calculated as: Δ = Rv / K where Rv = vertical reaction force at the support bearing as obtained from structural analysis K = dynamic stiffness of the support bearing as determined in A minimum precompression strain shall be maintained in the specimen throughout the duration of the test. This precompression strain shall be approximately equal to that present in a support bearing in a field installation. The magnitude of the applied cyclic strain shall be at least equal to the precompression strain. The minimum and maximum dynamic load shall be recorded at the beginning of the test. The minimum and maximum dynamic load shall be monitored and periodically recorded throughout the duration of the test. At the end of each applied displacement cycle, the displacement shall be held at the precompression level for no less than one half of the period of loading in order to facilitate heat dissipation. Artificial air flow devices (electrical fans) may be used to assist heat dissipation. Excessive heat generation will adversely affect the tested fatigue life. A specimen shall be accepted as having passed the fatigue test criteria after withstanding 2 million cycles of loading without failure. M 41-10 Page 6-55 Concrete Structures 6-02The following criteria shall constitute failure:

6-02.3(13)C26 Fatigue Testing Laboratory

Fatigue testing shall be performed by an independent testing laboratory. Facilities known to be capable of performing fatigue testing as specified are identified in

6-02.3(13)C27 Fabrication

The expansion joint systems shall be fabricated consistent with the details, dimensions, material specifications, and procedures delineated in the shop plans. All fabrication procedures shall be in conformance with the Standard Specifications and the Special Provisions. All expansion joint systems shall be fabricated by the same manufacturer. Metallic attachments used to secure elastomeric seals to the centerbeams, if welded to the centerbeams and edge beams, shall be welded continuously along both their top and bottom edges. All PTFE shall be bonded under controlled conditions and in strict accordance with written instructions provided by the PTFE manufacturer. All PTFE surfaces shall be smooth and free of bubbles after completion of bonding operations. All stainless steel sliding surfaces in contact with PTFE shall be polished to a Number 8 mirror finish. Each stainless steel sheet shall be welded to the steel backing plate in accordance with current AWS specifications. The stainless steel sheet shall be clamped to provide full contact with the steel backing plate during welding. The welds shall not protrude above the sliding surface of the stainless steel sheet. Page 6-56 M 41-10

6-02 Concrete StructuresAll steel surfaces, except those surfaces beneath stainless steel sheet, those to be bonded

to PTFE, or those in direct contact with strip seals, shall be protected against corrosion by one of the following methods:

6-02.3(13)C28 Inspection

Each expansion joint system shall be subjected to and shall pass three levels of inspection in order to be accepted. These three levels are Quality Control Inspection, Quality Assurance Inspection, and Final Inspection. The manufacturer shall provide both Quality Control Inspection and Quality Assurance Inspection. The Contractor shall provide access to the Engineer for the Final Inspection. Quality control inspection shall be provided by the manufacturer on a full time basis during the fabrication process of all major components to assure that the materials and Work meet or exceed the minimum requirements of the contract. Quality control inspection shall be performed by an entity having a line of responsibility distinctly different from that of the manufacturer’s fabrication department. Quality assurance inspection shall be performed by an independent inspection agency provided by the manufacturer. Quality assurance inspection is not required to be full time inspection but shall be performed during all phases of the manufacturing process. Final inspection of each expansion joint system will be performed by the Engineer at the job site immediately prior to installation. The Contractor shall provide an accessible work area for this inspection. During final inspection, the Engineer will inspect each expansion joint system for proper alignment, complete bond between expansion joint strip seals and steel components, and proper steel stud placement. There shall be no bends or kinks in the steel components, except as required to follow bridge deck grades and as specifically detailed on the shop plans. Straightening of unintended bends or kinks will not be permitted. All expansion joint systems exhibiting bends or kinks, other than those shown on the shop plans, shall be removed from the job site and replaced with a new expansion joint system at the expense of the Contractor. Expansion joint strip seals not fully bonded to the steel shall be fully bonded at no additional expense to the Contracting Agency. Studs will be visually inspected and will be struck lightly with a hammer. Studs that do not have a complete end weld or emit tintinnabulation when struck lightly with a hammer shall be replaced. Studs located more than one inch, in any direction, from the location specified on the shop plans shall be carefully removed and a new stud shall be welded in the proper location. All stud replacements shall be at no additional expense to the Contracting Agency.

6-02.3(13)C29 Acceptance

Each expansion joint system shall pass all three levels of inspection specified in Section

6-02.3(13)C28 to qualify for acceptance. Expansion joint systems which fail any one of the

three levels of inspection shall be replaced or repaired at no expense to the Contracting Agency and to the satisfaction of the Engineer. All proposed remedial procedures shall be submitted as Type 2E Working Drawings. M 41-10 Page 6-57 Concrete Structures 6-02The Contractor shall ascertain that the manufacturer has met the fatigue resistance characterization and prequalification requirements of Sections 6-02.3(13)C1 and

6-02.3(13)C2 applicable to the specific expansion joint system being installed. The

Contractor shall be responsible for all additional costs and/or time delays associated with selection of an alternative expansion joint system incurred as a result of noncompliance with these requirements, including the failure of the manufacturer to retest revised details or material substitutions of a previously prequalified system.

6-02.3(13)C30 Shipping and Handling

The expansion joint system shall be delivered to the job site and stored in accordance with the manufacturer’s shop plans. Lifting mechanisms, temperature adjustment devices, and temporary anchorages shall not be welded to the centerbeams or edge beams. Damage to the expansion joint system during shipping or handling shall be just cause for rejection of the expansion joint system. Damage to the corrosion protection system shall be repaired to the satisfaction of the Engineer.

6-02.3(13)C31 Pre-Installation Conference

A pre-installation conference shall be held 5 to 10-working days before the scheduled installation of the modular expansion joint assembly. The purpose of the conference shall be to discuss construction procedures, personnel, equipment to be used, methods to address congestion surrounding the assembly due to bridge deck steel reinforcing bars, expansion joint assembly supports and construction aids, and concrete placement and consolidation operations, including specific placement and consolidation surrounding the assembly support boxes. Those attending shall include, at a minimum, the superintendent, foremen in charge of erecting the joint assembly and placing the concrete encapsulating the assembly, and representatives from the modular expansion joint assembly manufacturer. If the project includes more than one modular expansion joint assembly, and if the Contractor’s key personnel change between installation operations, or at the request of the Engineer, additional conferences shall be held before each modular expansion joint assembly installation.

6-02.3(13)C32 Installation

A qualified installation technician shall be present at the job site to assure proper installation of each expansion joint system. This technician shall be a full time employee of the manufacturer of the specific expansion joint system being installed. The Contractor shall comply with all recommendations made by the expansion joint manufacturer’s installation technician. Each expansion joint system manufacturer’s installation technician shall certify to the Engineer that the manufacturer recommended installation procedures were followed. All certifications to the Engineer shall be in writing and shall be signed and dated by the manufacturer’s installation technician. Each expansion joint system shall be installed in strict accordance with the manufacturer’s shop plans under Section 6-02.3(13)C2 and the recommendations of the manufacturer’s installation technician. All centerbeam welded field splices shall be performed by a certified welder under the direct supervision of the manufacturer’s qualified installation technician as specified above. The weld procedure shall have been submitted by the manufacturer and accepted in accordance with Section 6-02.3(13)C2 . The welder shall have been trained and certified for performing those specific welds in accordance with the current AASHTO/AWS D1.5 Bridge Welding Code. Each permanently installed expansion joint system shall match exactly the finished bridge deck profile and grades. Page 6-58 M 41-10

6-02 Concrete StructuresThe Contractor shall exercise care at all times to protect each expansion joint system from

damage. The Contractor shall protect concrete blockouts and supporting systems from damage and construction traffic prior to installation of the expansion joint systems. After installation, construction loads shall not be allowed on the expansion joint systems. The Contractor shall submit a Type 2 Working Drawing consisting of a proposed method of bridging over each expansion joint system to accommodate construction traffic. Each expansion joint system shall be set to a gap width corresponding to the ambient temperature at the time of setting. This information is specified in the Plans and shall also be specified on the shop plans. All mechanical devices supplied by the joint system manufacturer, for the purpose of setting the expansion joint system to the proper gap width, will remain the property of the manufacturer. When no longer required, the devices shall be returned to the manufacturer. All forms and debris that may impede movement of the expansion joint systems shall be removed. Each expansion joint system shall be tested for watertightness after installation. The Contractor shall flood each completely installed expansion joint system with water to a minimum depth of three inches for a duration of at least one hour. If leakage is observed, the expansion joint system shall be repaired to the satisfaction of the Engineer at the Contractor’s expense. The repair procedure shall be prepared by the expansion joint system manufacturer and shall be submitted as a Type 2 Working Drawing. After repairs are completed, the expansion joint shall be retested for leakage.

6-02.3(14) Finishing Concrete Surfaces

All concrete shall show a smooth, dense, uniform surface after the forms are removed. If it is porous, the Contractor shall bear the cost of repairing it. The Contractor shall clean and refinish stained or discolored surfaces. Subsections A and B (below) describe two classes of surface finishing.

6-02.3(14)A Class 1 Surface Finish

The Contractor shall apply a Class 1 finish to all surfaces of concrete members to the limits designated in the Contract Plans. The Contractor shall follow steps 1 through 8 below. When steel forms have been used and when the surface of filled holes matches the texture and color of the area around them, the Contractor may omit steps 3 through 8. To create a Class 1 surface, the Contractor shall:

6-02.3(14)C Pigmented Sealer for Concrete Surfaces

The Contractor shall submit a Type 1 Working Drawing consisting of the pigmented sealer manufacturer’s written instructions covering, at a minimum, the following:

6-02.3(14)D Concrete Surface Finishes Produced by Form Liners

The concrete finishes listed in the table below shall be accomplished by the use of either a form liner selected from the products listed in the WSDOT Qualified Products List (QPL), or a form liner accepted by the State Bridge and Structures Architect and the Engineer. For acceptance of form liners not listed in the current WSDOT QPL, the Contractor shall submit Type 3 Working Drawings consisting of catalog cuts, other descriptive supporting information, and a 2-foot square physical sample of the form liner. Page 6-60 M 41-10

6-02 Concrete StructuresConcrete FinishHorizontal joints in elastomeric form liners

are permitted on surfaces greater than 8 feet in height1 provided that the minimum form liner panel dimensions are: Height (ft) Width (ft) Fractured Basalt Finish 8 2 Fractured Fin Finish 8 8 Fractured Granite Finish 8 8 Variable Depth Random Board Finish 8 8 3/4 Inch Random Board Finish 8 8 Ribbed Finish 8 8 Striated Finish 8 8 Ashlar Stone Finish 8 8 Block Finish 8 8 Split Face Finish 8 6 River Rock Finish 4 8 Cascadian Stone Finish 4 8 14 feet in height for River Rock Finish and Cascadian Stone Finish Variable Depth Random Board Finish shall utilize an elastomeric form liner. 3/4 Inch Random Board Finish shall utilize either an elastomeric or a plastic form liner. When specified in Contract documents to use wooden form liners, the concrete surface finish shall be achieved with reusable wooden form liners meeting the requirements of this Section and Section 6-02.3(14)D1 . For Cascadian Stone Finish, no partial rocks will be allowed in the finished pattern. The pattern shall be continuous across butt joints. Horizontal and vertical joints shall be adjusted as needed. Form liners shall be placed with the pillars, fins, board lines and faux mortar/other joints normal to grade for barrier applications and vertical for all other applications. Horizontal and vertical joints in ABS, plastic, or elastomeric form liners shall be spliced in accordance with the manufacturer’s printed instructions. The Contractor shall submit a Type 1 Working Drawing consisting of the manufacturer’s joint splice instructions. Once the forms are removed, the Contractor shall treat the joint areas by patching or light sandblasting as required by the Engineer to ensure that the joints are not visible. The concrete formed with ABS and plastic form liners shall be given a light sandblast to remove the glossy finish. Form liners shall be cleaned, reconditioned, and repaired before each use. Form liners with repairs, patches, or defects which, in the opinion of the Engineer, would result in adverse effects to the concrete finish shall not be used. Care shall be taken to ensure uniformity of color throughout the textured surface. A change in form release agent will not be allowed. All surfaces formed by the form liner shall also receive a Class 2 surface finish. Form ties shall be a type that leaves a clean hole when removed. All spalls and form tie holes shall be filled as specified for a Class 2 surface finish. M 41-10 Page 6-61 Concrete Structures 6-026-02.3(14)D1 3/4 Inch Random Board Finish Using Wooden Form Liners The reusable wooden form liners shall conform to Section 6-02.3(17)J and the texture pattern shown in the Plans. The texture pattern shall be accomplished with 3/4 inch thick battens in varying widths applied to the surface of the forms. The edge of all battens shall be sloped 15 degrees to facilitate form removal. The Contractor shall submit a Type 3 Working Drawing consisting of a concrete panel test section, with the 3/4 inch random board texture to be used and based on the pattern shown in the Plans. The test section shall be constructed using the forms and materials intended to construct the permanent structures. The test section shall be composed of two ten foot by ten foot form sections which shall be assembled to make a ten foot by 20 foot concrete surface section, and shall include the wall top treatment, and one horizontal joint treatment. All cracks, holes, slits, gaps, and apertures in forms shall be plugged and caulked with molding plaster to remain completely watertight and withstand the pressures of concrete placement. Joints between the form units shall be sealed with silicone or latex caulking compound. Butt joints may be sealed with non-absorptive sponge tape. Construction joints and expansion joints shall be incorporated into the pattern of the face treatment. Forms and form ties shall be designed to permit removal without damaging the finish. Prying against the face of the concrete will not be allowed. Storage of formwork and form materials shall be in a manner to prevent damage or distortion. All damage to formwork during placing, removal, or storage shall be repaired by the Contractor at no additional expense to the Contracting Agency.

6-02.3(14)E Exposed Aggregate Finish

6-02.3(14)E1 Submittals

The Contractor shall submit Type 2 Working Drawings consisting of the following items:

6-02.3(14)E2 Producing Exposed Aggregate Finish

The Contractor shall produce all exposed aggregate concrete in accordance with procedure and equipment outlined in the Type 2 Working Drawing submittal. The exposed aggregate shall achieve the same final effect as demonstrated on the sample panel accepted by the Engineer. Formwork shall be cleaned, reconditioned, and repaired before each use. Formwork with repairs, patches or defects which, in the opinion of the Engineer, would result in adverse effects to the concrete finish shall not be used. Page 6-62 M 41-10

6-02 Concrete StructuresForms and form joints shall remain completely watertight. Butt joints and joints between

form units used on surfaces which are to receive an exposed aggregate finish shall be tongue and grooved, or splined and shall be sealed with a caulking compound. As an alternative to using tongue and grooved or splined joints, a closed cell polyvinylchloride foam sealer of 3/16 inch thickness with pressure-sensitive adhesive on one or both sides may be used to seal the butt joints between form units. The foam sealer shall be recessed by an amount such that when the form units are compressed to their final position, the foam sealer will be flush with the face of the form units. Adjacent formwork panels, if used, shall be in line and no offset shall occur between panels. Forms for the exposed aggregate surface for members not yet supporting loads, including the members own load, may be removed as required to affect the exposed aggregate surface, provided the concrete has a minimum age of twelve hours and is of sufficient strength and hardness so as not to be damaged by the form removal operations and provided that curing and protection operations are maintained. Removal of forms on the remaining concrete surfaces shall be in accordance with After the forms are stripped, the surface mortar shall be removed from the areas specified to receive the exposed aggregate finish. The exposed aggregate finish shall be obtained by either one or a combination of the two methods described in Sections 6-02.3(14)E3 and 6-02.3(14)E4 as necessary to provide the specified exposed aggregate finish.

6-02.3(14)E3 Retardant Coating Method

A retardant coating conforming to Section 9-08.3(2)A shall be applied to the formwork where concrete surfaces with exposed aggregate finish are shown in the Plans. For cast-in-place concrete the retardant shall have an effective life of not less than the length of time required for the Class EA concrete to be in place prior to the removal of forms plus 12 hours. For slip-formed concrete barrier and horizontal to near-horizontal applications, the retardant shall have an effective life of not less than 24 hours. The Contractor shall remove the surface mortar two to three hours after applying the retardant coating. Retardant shall be applied in accordance with the manufacturer’s instructions to remove the surface mortar. The sealer and form release agent used on the form shall be compatible with the retardant and shall not react with the retardant to produce an undesirable effect on the exposed aggregate finish. The sealer and form release agent to be used on the form shall be as recommended by the manufacturer of the retardant. Surface mortar shall be removed using one of the following methods:

6-02.3(14)E4 Abrasive Blasting Method

As soon as forms are stripped, the exposed aggregate areas shall be abrasive blasted to remove the surface mortar. For slip-formed concrete barrier and horizontal to near- horizontal applications, this shall be done once the concrete has attained a minimum age of 12 hours and is of sufficient strength and hardness to prevent damage. M 41-10 Page 6-63 Concrete Structures 6-02Adjacent materials and finishes shall be protected from dust, dirt and other damage during abrasive blasting operations. Corners and edge of patterns shall be carefully blasted using back-up boards to maintain a uniform corner or edge line. The abrasive blast finishing shall be done in as continuous an operation as possible, utilizing the same work crew to maintain continuity of finish on each surface or area of work. The type and gradation of abrasive grit used, the type of nozzle, nozzle pressure, and blasting techniques shall be as specified in the Type 2 Working Drawing submittal, and as required to expose the aggregate. The Contractor shall be responsible for safety of the workers and shall equip each with air-fed helmets. The Contractor shall provide suitable enclosures for the collection of grit and dust from the abrasive blasting operation. After receiving the Engineer’s acceptance of the exposed aggregate finish, a 10 percent muriatic acid wash shall be applied to the exposed aggregate surfaces. Surfaces shall be flushed thoroughly with water following a 5 to 10 minute interaction period between the acid solution and the surface. All stains and streaks on the exposed aggregate surface shall be removed before applying the clear sealer.

6-02.3(14)E5 Applying Clear Sealer

Two seal coatings of clear sealer conforming to Section 9-08.3(2)B shall be applied to the exposed aggregate surfaces in accordance with the manufacturer’s recommended procedure.

6-02.3(14)E6 Containment

When producing exposed aggregate finish on concrete surfaces over water, the Contractor shall exercise care and use suitable means to collect and dispose of abrasives and chemical agents, and the resulting concrete surface mortar debris used in or resulting from the finishing of the exposed aggregate surfaces to prevent their entry into the environment surrounding the Structure.

6-02.3(14)F Permeon Treatment

The Contractor shall apply permeon treatment to all concrete surfaces specified in the Plans to receive permeon treatment. The Contractor shall use SAE AMS Standard 595 Color Number 30219 as the target color. The target color is intended as a reference for hue, and is not intended as a reference for opacity or luster. The Contractor is advised that this target color is based on the concentration formula and application rate identified in the QPL for each product. The concentration formula and application rate for products not listed in the QPL will be determined by the Engineer. The permeon treatment shall be applied only by personnel approved by the manufacturer to apply the product. The Contractor shall furnish certificates of approval from the manufacturer, for the personnel scheduled to perform the work, to the Engineer prior to beginning the treatment operation. The concrete shall be cured for the time period recommended by the manufacturer prior to receiving the permeon treatment coating. The Contractor shall clean and prepare the concrete surfaces in accordance with the recommendations of the manufacturer for the use of the treatment product. The Contractor shall apply the permeon treatment to the surfaces specified, in accordance with the recommendations of the manufacturer for the use of the treatment product. The Contractor shall prevent permeon treatment from reaching surfaces not specified to receive the permeon treatment. Page 6-64 M 41-10

6-02 Concrete StructuresThe Contractor shall prevent pigmented sealer from reaching surfaces that have received

permeon treatment. Should pigmented sealer reach surfaces that have received permeon treatment, the pigmented sealer shall be removed and the permeon treatment repaired in accordance with Section 1-07.13 .

6-02.3(15) Date Numerals

Standard date numerals shall be placed where shown in the Plans. The date shall be for the year in which the Structure is completed. When an existing Structure is widened or when traffic barrier is placed on an existing Structure, the date shall be for the year in which the original Structure was completed. Unit Contract prices shall cover all costs relating to these numerals.

6-02.3(16) Plans for Falsework and Formwork

The Contractor shall submit all plans for falsework and formwork as Type 2E Working Drawings. A submittal is not required for footing or retaining wall formwork if the concrete placement is 4 feet or less in height. Formwork plans are required for fixed form barriers regardless of height. The design of falsework and formwork shall be based on:

6-02.3(17)A ;

6-02.3(16)A Vacant

M 41-10 Page 6-65 Concrete Structures 6-026-02.3(16)B Pre-Contract Review of Falsework and Formwork Plans The Contractor may request pre-contract review of formwork plans for abutments, wingwalls, diaphragms, retaining walls, columns, girders and beams, box Structures, railings, and bulkheads. Plans for falsework supporting the bridge deck for interior spans between precast prestressed concrete girders may also be submitted for pre-contract review. To obtain pre-contract review, the Contractor shall electronically submit drawings and design calculations in PDF format directly to: BridgeConstructionSupport@wsdot.wa.gov The Bridge and Structures Office, Construction Support Engineer will return the falsework or formwork plan to the Contractor with review notes, an effective date of review, and revisions needed prior to use. For each contract on which the pre-reviewed falsework or formwork plans will be used, the Contractor shall submit a copy to the Engineer. Construction shall not begin until the Engineer has given concurrence. If the falsework or formwork being constructed has deviations to the preapproved falsework or formwork plan, the Contractor shall submit plan revisions for review and approval in accordance with Section 6-02.3(16) .

6-02.3(17) Falsework and Formwork

Formwork and falsework are both structural systems. Formwork contains the lateral pressure exerted by concrete placed in the forms. Falsework supports the vertical and/ or the horizontal loads of the formwork, reinforcing steel, concrete, and live loads during construction. The Contractor shall set falsework, to produce in the finished Structure, the lines and grades indicated in the Contract Plans. The setting of falsework shall allow for shrinkage, settlement, falsework girder camber, and all structural camber the Plans or the Engineer require. Concrete forms shall be mortar tight, true to the dimensions, lines, and grades of the Structure. Curved surfaces shown in the Contract Plans shall be constructed as curved surfaces and not chorded, except as allowed in Section 6-02.3(17)J . Concrete formwork shall be of sufficient strength and stiffness to prevent overstress and excess deflection as defined in Section 6-02.3(17)B . The rate of depositing concrete in the forms shall not exceed the placement rate in the formwork plan Working Drawing. The interior form shape and dimensions shall also ensure that the finished concrete will conform with the Contract Plans. If the new Structure is near or part of an existing one, the Contractor shall not use the existing Structure to suspend or support falsework unless the Plans or Special Provisions state otherwise. For prestressed girder and T-beam bridge widenings or stage construction, the bridge deck and the diaphragm forms may be supported from the existing Structure or previous stage, if accepted by the Engineer. For steel plate girder bridge widenings or stage construction, only the bridge deck forms may be supported from the existing Structure or previous stage, if accepted by the Engineer. See Section

6-02.3(17)E for additional conditions.

On bridge decks, forms designed to stay in place made of steel or precast concrete panels shall not be used. For post-tensioned Structures, both falsework and forms shall be designed to carry the additional loads caused by the post-tensioning operations. The Contractor shall construct supporting falsework in a way that leaves the Superstructure free to contract and lift off the falsework during post-tensioning. Forms that will remain inside box girders to support the placement of the bridge deck concrete shall, by design, resist girder contraction as little as possible. See Section 6-02.3(26) for additional conditions. Page 6-66 M 41-10

6-02 Concrete Structures6-02.3(17)A Design Loads

The design load for falsework shall consist of the sum of dead and live vertical loads, and a design horizontal load. The minimum total design load for any falsework shall not be less than 100 lbs/sf for combined live and dead load regardless of Structure thickness. The entire Superstructure cross-section, except traffic barrier, shall be considered to be placed at one time for purposes of determining support requirements and designing falsework girders for their stresses and deflections, except as follows: For concrete box girder bridges, the girder stem, diaphragms, crossbeam and connected bottom slabs may be considered self-supporting between the falsework bents at the time the top slab is place provided the following conditions are true:

6-02.3(17)B Allowable Design Stresses and Deflections

The maximum allowable stresses listed in this section are based on the use of identifiable, undamaged, high-quality materials. Stresses shall be appropriately reduced if lesser quality materials are to be used. These maximum allowable stresses include all adjustment factors, such as the short-term load duration factor. The maximum allowable stresses and deflections used in the design of the falsework and formwork shall be as follows:

6-02.3(17)B1 Deflection

Deflection resulting from dead load and concrete pressure for exposed visible surfaces shall not exceed 1/360 of the span. Deflection resulting from dead load and concrete pressure for unexposed non-visible surfaces, including the bottom of the deck slab between girders shall not exceed 1/270 of the span. In the foregoing, the span length shall be the center line to center line distance between supports for simple and continuous spans, and from the center line of support to the Page 6-68 M 41-10

6-02 Concrete Structuresend of the member for cantilever spans. For plywood supported on members wider than

1½ inches, the span length shall be taken as the clear span plus 1½ inches. Also, dead load shall include the weight of all successive placements of concrete, reinforcing steel, forms and falsework self weight. Only the self weight of falsework girders may be excluded from the calculation of the above deflections provided that the falsework girder deflection is compensated for by the installation of camber strips. Where successive placements of concrete are to act compositely in the completed Structure, deflection control becomes extremely critical. Maximum deflection of supporting members shall not exceed 1/500 of the span for members constructed in several successive placements (such as concrete box girder and concrete T-beam girder Structures). Falsework components shall be sized, positioned, and/or supported to minimize progressive increases in deflection of the Structure which would preload the concrete or reinforcing steel before it becomes fully composite.

6-02.3(17)B2 Timber

Each species and grade of timber/lumber used in constructing falsework and formwork shall be identified in the drawings. The allowable stresses and loads shall not exceed the lesser of stresses and loads given in the table below or factored stresses for designated species and grade in Table 7.3 of the Timber Construction Manual, latest edition, by the American Institute of Timber Construction. Compression perpendicular to the grain reduced to 300 psi for use when moisture content is 19 percent or more (areas exposed to rain, concrete curing water, green lumber).450 psi Compression parallel to the grain but not to exceed 1,500 psi.480,000 psi (L/d)2 Flexural stress for members with a nominal depth greater than 8 inches.1,800 psi Flexural stress psi for members with a nominal depth of 8 inches or less.1,500 psi The maximum horizontal shear. 140 psi AXIAL tension. 1,200 psi The maximum modulus of elasticity (E) for timber. 1,600,000 psi Where: L is the unsupported length; and d is the least dimension of a square or rectangular column, or the width of a square of equivalent cross-sectional area for round columns. The allowable stress for compression perpendicular to the grain, and for horizontal shear shall not be increased by any factors such as short duration loading. Additional requirements are found in other parts of Section 6-02.3(17) . Criteria for the design of lumber and timber connections are found in Section 6-02.3(17)I. Plywood for formwork shall be designed in accordance with the methods and stresses allowed in the APA Design/Construction Guide for Concrete Forming as published by the American Plywood Association, Tacoma, Washington. As concrete forming is a special application for plywood, wet stresses shall be used and then adjusted for forming conditions such as duration of load, and experience factors. Concrete pour pressures shall be in accordance with Section 6-02.3(17)J . M 41-10 Page 6-69 Concrete Structures 6-026-02.3(17)B3 S teel For identified grades of steel, design stresses shall not exceed those specified in the Steel Construction Manual, latest edition, by the American Institute of Steel Construction, except as follows: Compression, flexural but not to exceed 0.6Fy 12,000,000 psi Ld/bt The modulus of elasticity (E) shall be 29,000,000 psi When the grade of steel cannot be positively identified as with salvaged steel and if rivets are present, design stresses shall not exceed the following: Yield point fy30,000 psi Tension, axial, and flexural 16,000 psi Compression, axial except L/r shall not exceed 120 14,150 - 0.37(KL/r)2 psi Shear on gross section of the web of rolled shapes 9,500 psi Web crippling for rolled shapes 22,500 psi Compression, flexural but not to exceed 16,000 psi and L/b not greater than 3916,000 - 5.2(L/b)2 psi The modulus of elasticity (E) shall be 29,000,000 psi Where: L is the unsupported length; d is the least dimension o f rectangular columns, or the width of a square of equivalent cross-sectional area for round columns, or the depth of beams; b is the flang e width; t is the thickness o f the compression flange; r is the r adius of gyration of the compression flange about the weak axis of the member; and Fy is the specified minimum yield stress, psi, for the grade of steel used. All dimensions are expressed in inches.

6-02.3(17)C Falsework and Formwork at Special Locations

In addition to the minimum requirements specified in Sections 6-02.3(17)A and

6-02.3(17) B, falsework towers or posts supporting beams directly over Roadways or

railroads which are open to traffic or the public shall be designed and constructed so that the falsework will be stable if subjected to impact by vehicles. The use of damaged materials, unidentifiable material, salvaged steel or steel with burned holes or questionable weldments shall not be used for falsework described in this section. For the purposes of this Specification the following public or private facilities shall also be considered as “Roadways”: pedestrian pathways and other Structures such as bridges, walls, and buildings. The dimensions of the clear openings to be provided through the falsework for Roadways, railroads, or pedestrian pathways shall be as specified in the Contract. Falsework posts or shoring tower systems which support members that cross over a Roadway or railroad shall be considered as adjacent to Roadways or railroads. Other falsework posts or shoring towers shall be considered as adjacent to Roadways or railroads only if the following conditions apply: 1.L ocated in the row of falsework posts or shoring towers nearest to the Roadway or railroad; and Page 6-70 M 41-10

6-02 Concrete Structures2. Horizontal distance from the traffic side of the falsework to the edge of pavement

is less than the total height of the falsework and forms; or

1-07.23 and 6-02.3(17)M . The falsework design at special locations, shall incorporate

the minimum requirements detailed in this section, even if protected by concrete median barrier. The vertical load used for the design of falsework posts and towers which support the portion of the falsework over openings, shall be the greater of the following:

6-02.3(17)D Falsework Support Systems: Foundations, Manufactured Shoring Towers,

Caps, and Posts Foundations for falsework shall be designed for conditions stated in this Section using methods shown in the AASHTO Standard Specifications for Highway Bridges Seventeenth Edition – 2002 for allowable stress design, the AASHTO LRFD Bridge Design Specifications for load and resistance factor design or the AASHTO Guide Design Specifications for Bridge Temporary Works . Allowable stresses for materials shall not exceed stresses and conditions allowed by Section 6-02.3(17)B .

6-02.3(17)D1 Vacant

6-02.3(17)D2 Vacant

6-02.3(17)D3 Bents, Shoring Towers, Piling, Posts, and Caps

Plans for falsework bents or shoring tower systems, including manufactured tower systems shall have plan, cross-section, and elevation view scale drawings showing all geometry. Show in the falsework plans the proximity of falsework to utilities and all other nearby Structures including underground Structures. The ground elevation, cross-slopes, relation of stringers to one another, and dimensions to posts or piling shall be shown in the falsework plans. Column, pile, or tower heights shall be indicated. Member sizes, wall thickness and diameter of steel pipe columns or piles shall be shown in the falsework plans. Location of wedges, minimum bearing area and type of wedge material shall be identified in the falsework plans. Bracing size, location, material and all connections shall be described in the falsework plans. The relationship of the falsework bents or shoring tower systems to the permanent Structure’s pier and footing shall be shown. Load paths shall be as direct as possible. Loads shall be applied through the shear centers of all members to avoid torsion and buckling conditions. Where loads cause twisting, biaxial bending, or axial loading with bending, the affected members shall be designed for combined stresses and stability. Posts or columns shall be constructed plumb with tops and bottoms carefully cut to provide full end bearing. Caps shall be installed at all bents supported by posts or piling unless the falsework Working Drawings specifically permit otherwise. Caps shall be fastened to the piling or posts. The falsework shall be capable of supporting non uniform or localized loading without adverse effect. For example, the loading of cantilevered ends of stringers or caps shall not cause a condition of instability in the adjacent unloaded members. Page 6-72 M 41-10

6-02 Concrete StructuresTimber posts and piling shall be fastened to the caps and mudsills by through-bolted

connections, drift pins, or other accepted connections. The minimum diameter of round timber posts shall be shown in the falsework plans. Timber caps and timber mudsills shall be checked for crushing from columns or piling under maximum load. Steel posts and piling shall be welded or bolted to the caps and shall be bolted or welded to the foundation. Steel members shall be checked for buckling, web yielding, and web crippling. Wedges shall be used to permit formwork to be taken up and released uniformly. Wedges shall be oak or close-grained Douglas fir. Cedar wedges or shims shall not be used anywhere in a falsework or forming system. Wedges shall be used at the top or bottom of shores, but not at both top and bottom. After the final adjustment of the shore elevation is complete, the wedges shall be fastened securely to the sill or cap beam. Only one set of wedges (with one optional block) shall be used at one location. Screw jacks (or other allowed devices) shall be used under arches to allow incremental release of the falsework. Sand jacks may be used to support falsework and are used for falsework lowering only. Sand jacks shall be constructed of steel with snug fitting steel or concrete pistons. Sand jacks shall be filled with dry sand and the jack protected from moisture throughout its use. They shall be designed and installed in such a way to prevent the unintentional migration or loss of sand. All sand jacks shall be tested in accordance with Section 6-02.3(17)G . When falsework is over or adjacent to Roadways or railroads, all details of the falsework system which contribute to the horizontal stability and resistance to impact shall be installed at the time each element of the falsework is erected and shall remain in place until the falsework is removed. For other requirements see Section 6-02.3(17)C . Transverse construction joints in the Superstructure shall be supported by falsework at the joint location. The falsework shall be constructed in such a manner that subsequent pours will not produce additional stresses in the concrete already in place.

6-02.3(17)D4 Manufactured Shoring Tower Systems and Devices

Manufactured proprietary shoring tower systems shall be identified in the falsework plans by make and model and safe working load capacity per leg. The safe working load for shoring tower systems shall be based upon a minimum 2½ to 1 factor of safety. The safe working load capacity, anticipated deflection (or settlement), make and model shall be identified in the falsework plans for manufactured devices such as: single shores, overhang brackets, support bracket and jack assemblies, friction collars and clamps, hangers, saddles, and sand jacks. The safe working load for shop manufactured devices shall be based on a minimum ultimate strength safety factor of 2 to 1. The safe working load for field fabricated devices and all single shores shall be based on a minimum ultimate strength safety factor of 3 to 1. The safe working load of all devices shall not be exceeded. The design loads shall be as defined by Section 6-02.3(17)A . The maximum allowable free end deflection of deck overhang brackets under working loads applied shall not exceed 3/16 inch measured at the edge of the concrete slab regardless of the fact that the deflection may be compensated for by pre-cambering or of setting the elevations high. The Contractor shall comply with all manufacturer’s specifications; including those relating to bolt torque, placing washers under nuts and bolt heads, cleaning and oiling of parts, and the reuse of material. Devices which are deteriorated, bent, warped, or have poorly fitted connections or welds, shall not be installed. Shoring tower or device capacity as shown in catalogs or brochures published by the manufacturer shall be considered as the maximum load which the shoring is able to safely support under ideal conditions. These maximum values shall be reduced for adverse loading conditions; such as horizontal loads, eccentricity due to unbalanced spans or placing sequence, and uneven foundation settlement. M 41-10 Page 6-73 Concrete Structures 6-02Copies of catalog data and/or other technical data shall be furnished with the falsework plans to verify the load-carrying capacity, deflection, and manufacturers installation requirements of all manufactured products or devices proposed for use. Upon request by the Engineer, the Contractor shall furnish manufacturer certified test reports and results showing load capacity, deflection, test installation conditions, and identify associated components and hardware for shoring tower systems or other devices. In addition to manufacturer’s requirements, the criteria shown in the following sections for manufactured proprietary shoring tower systems and devices shall be complied with when preparing falsework plans, calculations, and installing these shoring tower systems and devices as falsework. Alternative criteria and/or systems shall be submitted as a Type 2 Working Drawing consisting of a written statement on the manufacturer’s letterhead, signed by the shoring or device manufacturer (not signed by a material supplier or the Contractor) addressing the following:

6-02.3(17)A Minimum bracing criteria and allowable leg loads are described in the

following paragraphs. All shoring tower systems and bracing shall be thoroughly inspected by the Contractor for plumb vertical support members, secure connections, and straight bracing members immediately prior to, at intervals during, and immediately after every concrete placement. For manufactured shoring tower systems, the maximum allowable deviation from the vertical is ⅛ inch in 3 feet. If this tolerance is exceeded, concrete shall not be placed until adjustments have brought the shoring towers within the acceptable tolerance. Page 6-74 M 41-10

6-02 Concrete Structures6-02.3(17)E Stringers, Beams, Joists, Bridge Deck Support, and Deck Overhangs

All stringers, beams, joists, and bridge deck support shall be designed for the design loads, deflections, and allowable stresses described in the preceding Section 6-02.3(17)A , B, and C and for the following conditions. At points of support, stringers, beams, joists, and trusses shall be restrained against rotation about their longitudinal axis. The effect of biaxial bending shall be investigated in all cases where falsework beams are not set plumb and the Structure cross-slope exceeds 3 percent. For box girder and T-beam bridges, the centerline of falsework beams or stringers shall be located within 2 feet of the bridge girder stems and preferably directly under the stems or webs. Stringers supporting formwork for concrete box girder and T-beam slab overhangs shall be stiff enough so that the differential deflection due to the placement of bridge deck concrete is no more than 3/16 inch between the outside edge of the bridge deck and the exterior web even if camber strips can compensate for the deflection. Friction shall not be relied upon for lateral stability of beams or stringers. If the compression flange of a beam is not laterally restrained, the allowable bending stress shall be reduced to prevent flange buckling. If flange restraint is provided and since it is impossible to predict the direction in which a compression flange will buckle, positive restraint shall be provided in both directions. Flange restraint shall be designed for a minimum load of 2 percent of the calculated compression force in the beam flange at the point under consideration. Camber strips shall be used to compensate for falsework take-up and deflection, vertical alignment, and the anticipated Structure dead load deflection shown in the camber diagram in the Contract Plans. Camber is the adjustment to the profile of a load- supporting beam or stringer so that the completed Structure will have the lines and grades shown in the Plans. The dead load camber diagram shown in the Contract Plans is the predicted Structure dead load deflection due to weight of applied concrete loads. This dead load camber shall be increased by:

6-02.3(17)F Bracing

All falsework bracing systems shall be designed to resist the horizontal design load in all directions with the falsework in either the loaded or unloaded condition. All bracing, connection details, specific locations of connections, and hardware used shall be shown in the falsework plans. Falsework diagonal bracing shall be thoroughly analyzed with particular attention given to the connections. The allowable stresses in the diagonal braces may be controlled by the joint strength or the compression stability of the diagonal. Timber bracing for timber falsework bents shall have connections designed in accordance with Section 6-02.3(17)I . All damaged cross-bracing, such as split timber members shall be replaced. Steel strapping shall avoid making sharp angles or right-angle bends. A means of preventing accidental loss of tension shall be provided for steel strapping. See Sections

6-02.3(17)A , B, and C for design loads and allowable stresses.

Bracing shall not be attached to concrete traffic barrier, guardrail posts, or guardrail. To prevent falsework beam or stringer compression flange buckling, cross-bracing members and connections shall be designed to carry tension as well as compression. All components, connection details and specific locations shall be shown in the falsework plans. Bracing, blocking, struts, and ties required for positive lateral restraint of beam flanges shall be installed at right angles to the beam in plan view. If possible, bracing in adjacent bays shall be set in the same transverse plane. However, if because of skew or other considerations, it is necessary to offset the bracing in adjacent bays, the offset distance shall not exceed twice the depth of the beam. All falsework and bracing shall be inspected by the Contractor for plumbness of vertical support members, secure connections, tight cables, and straight bracing members immediately prior to, during, and immediately after every concrete placement. Bracing shall be provided to withstand all imposed loads during erection of the falsework and all phases of construction for falsework adjacent to a Roadway, sidewalk, or railroad track which is open to the public. All details of the falsework system which contribute to horizontal stability and resistance to impact, including the bolts in bracing, shall be installed at the time each element of the falsework is erected and shall remain in place until the falsework is removed. The falsework plans shall show provisions for supplemental bracing or methods to be used to conform to this requirement during each phase of erection and removal. Wind loads shall be included in the design of such bracing or methods. Loads, connections, and materials for falsework adjacent to Roadways, shall also be in accordance with Section 6-02.3(17)C . Page 6-76 M 41-10

6-02 Concrete Structures6-02.3(17)F1 Cable or Tension Bracing Systems

When cables, wire rope, steel rod, or other types of tension bracing members are used as external bracing to resist horizontal forces, or as temporary bracing to support bents while falsework is being erected or removed adjacent to traffic, all elements of the bracing system shall be shown in the falsework plans. Bracing shall not be attached to concrete traffic barrier, guardrail posts, or guardrail. All damaged bracing, such as frayed and kinked guying systems shall be replaced. Wire rope shall avoid making sharp angles or right- angle bends and a means of preventing accidental loss of tension shall be provided. The following information shall be submitted as a Type 2 Working Drawing:

6-02 Concrete StructuresWire Rope Capacities

Safe Load in Pounds for New Plow Steel Hoisting Rope 6 Strands of 19-Wires, Hemp Center (Safety Factor of 6) Diameter inches Weight Lbs./Ft. Safe Load Lbs. ¼ 0.10 1,050 5/16 0.16 1,500 ⅜ 0.23 2,250 7/16 0.31 3,070 ½ 0.40 4,030 9/16 0.51 4,840 ⅝ 0.63 6,330 ¾ 0.95 7,930 ⅞ 1.29 10,730 1 1.60 15,000 1⅛ 2.03 18,600 1¼ 2.50 23,000 1⅜ 3.03 25,900 1½ 3.60 30,700 1⅝ 4.23 35,700 1¾ 4.90 41,300

6-02.3(17)F2 Applying Wire Rope Clips

The only correct method of attaching U-bolt wire rope clips to rope ends is to place the base (saddle) of the clip against the live end of the rope, while the “U” of the bolt presses against the dead end. The clips are usually spaced about six rope diameters apart to give adequate holding power. A wire-rope thimble shall be used in the loop eye to prevent kinking when wire rope clips are used. The correct number of clips for safe application, and spacing distances, are shown below: Number of Clips and Spacing for Safe Application Improved Plow Steel Rope Diameter inchesNumber of Clips Minimum Drop Forged Other Material Spacing (Inches) ⅜ 2 3 3 ½ 3 4 3½ ⅝ 3 4 4 ¾ 4 5 4½ ⅞ 4 5 5¼ 1 5 6 6 1⅛ 6 6 6¾ 1¼ 6 7 7½ 1⅜ 7 7 8¼ 1½ 7 8 9 M 41-10 Page 6-79 Concrete Structures 6-026-02.3(17)F3 Anchor Blocks Concrete anchor blocks and connections used to resist forces from external bracing shall be shown in the falsework plans. Concrete anchor blocks shall be proportioned to resist both sliding and overturning. When designing anchor block stability, the weight of the anchor block shall be reduced by the vertical component of the cable or brace tension to obtain the net or effective mass to be used in the anchorage computations. The coefficient of friction assumed in the design shall not exceed the following: Friction Coefficient Anchor block set on sand 0.40 Anchor block set on clay 0.50 Anchor block set on gravel 0.60 Anchor block set on pavement 0.60 Multiply the friction coefficient by 0.67 if it is likely the supporting material is wet or will become wet during the construction period. The method of connecting the cable or brace to the anchor block is part of the anchor block design. The connection shall be designed to resist both horizontal and vertical forces.

6-02.3(17)F4 Temporary Bracing for Bridge Girders During Erection

Steel girders shall be braced in accordance with Section 6-03.3(7)A . Prestressed concrete girders shall be braced sequentially during girder erection. The bracing shall be designed and detailed by the Contractor and shall be shown in the falsework/formwork Working Drawings. The Contractor shall furnish, install, and remove the bracing at no additional cost to the Contracting Agency. At a minimum, the Contractor shall brace girders at each end and at midspan to prevent lateral movement or rotation. This bracing shall be placed prior to the release of each girder from the erection equipment. If the bridge is constructed with cast-in-place concrete diaphragms, the bracing may be removed once the concrete in the diaphragms has been placed and cured for a minimum of 24 hours.

6-02.3(17)F5 Temporary Bracing for Bridge Girders During Diaphragm and Bridge Deck

Concrete Placement Girders shall be braced to resist all temporary and construction loads, including those caused by the placing of precast concrete deck panels and concrete for the bridge deck. At a minimum, the Contractor shall brace concrete girders to prevent relative lateral movement and rotation at a spacing not to exceed 60 feet. The Contractor may consider the bracing effects of the diaphragms. The Contractor shall account for the added load from concrete finishing machines and other construction loadings in the design of the bracing. Bracing shall be designed and detailed by the Contractor and shall be shown in the girder erection plan. Falsework support brackets and braces shall not be welded to structural steel bridge members or to steel reinforcing bars. These braces shall be furnished, installed, and removed by the Contractor at no additional expense to the Contracting Agency.

6-02.3(17)G Testing Falsework Devices

The Contractor shall establish the load capacity and deflection (or settlement) of all friction collars and clamps, brackets, hangers, saddles, sand jacks, and similar devices utilizing a recognized independent testing Laboratory accepted by the Engineer. Page 6-80 M 41-10

6-02 Concrete StructuresLaboratory tests shall use the same materials and design that will be used on the

project. Test loads shall be applied to the device in the same manner that the device will experience loading on the project. All bolts or threaded rods used with the device shall be identified as to diameter, length, type, grade, and torque. All wedges, blocks, or shims used with the device on the project shall also be tested with the device. All adjustable jack systems used as a part of a device shall be tested with the device and shall have its maximum safe working extended height identified. Devices shall not be tested in contact with the permanent Structure. Independent members with the same properties as the permanent Structure shall be used to test device connections. At least 14 days prior to the test, the Contractor shall submit a Type 2 Working Drawing consisting of the test procedure and scale drawing showing how the device will be tested and how data will be collected. The Contractor shall provide the Engineer an opportunity to witness these tests. The independent testing Laboratory shall provide a certified test report which shall be signed and dated. The test report shall clearly identify the device tested including trademarks and model numbers; identify all parts and materials used, including grade of steel, or lumber, member section dimensions; location, size, and the maximum tested extended height of all adjustable jacks; indicate condition of materials used in the device; indicate the size, length and location of all welds; indicate how much torque was used with all bolts and threaded rods. The report shall describe how the device was tested, report the results of the test, provide a scale drawing of the device showing the location(s) of where deflections or settlements were measured, and show where load was applied. Deflections or settlements shall be measured at load increments and the results shall be clearly graphed and labeled. Prior to installation of falsework devices named in this section, the Contractor shall submit Type 2 Working Drawings consisting of the certified test reports. The safe working load for shop manufactured devices named in this section shall be derived by dividing the ultimate strength by a safety factor of 2.0. The safe working load for field fabricated or field modified devices (including the use of timber blocks or wedges with the device) shall be determined by dividing the ultimate strength by a safety factor of 3.0. Working load shall include masses of all successive concrete placements, falsework, forms, all load transfer that takes place during post-tensioning, and all live loads; such as workers, Roadway finishing machines, and concrete delivery systems. The maximum allowable free end deflection of deck overhang brackets with combined dead and live working loads applied shall be 3/16 inch even though deflection may be compensated for by pre-cambering or setting the elevations high. The Contractor shall comply with all manufacturer’s specifications; including those relating to bolt torque, cleaning and oiling of parts, and the reuse of material. Devices which are deteriorated, bent, warped or have poorly fitted connections or welds, shall not be installed.

6-02.3(17)H Formwork Accessories

Formwork accessories such as form ties, form anchors, form hangers, anchoring inserts, and similar hardware shall be specifically identified in the formwork plans including the name and size of the hardware, manufacturer, safe working load, and factor of safety. The grade of steel shall also be indicated for threaded rods, coil rods, and similar hardware. Wire form ties shall not be used. Welding or clamping formwork accessories to Contract Plan reinforcing steel will not be allowed. Driven types of anchorages for fastening forms or form supports to concrete, and Contractor fabricated “J” hooks shall not be used. Field drilling of holes in prestressed girders is not allowed. M 41-10 Page 6-81 Concrete Structures 6-02Taper ties may be used provided the following conditions are met:

6-02 Concrete Structuresanchor shall be shown in the formwork drawing if it is assumed that the anchor will be

loaded before the concrete has reached its 28-day strength. Installation of permanent concrete inserts, such as form ties hangers, or embedded anchor assemblies, shall permit removal of all metal to at least ½ inch below the concrete surface. Holes shall be patched in accordance with Section 6-02.3(14) . During removal of the outer unit, the bond between the concrete and the inner unit or rod shall not be broken.

6-02.3(17)I Timber Connections

Timber connections shall be designed in accordance with the methods, stresses, and loads allowed in the Timber Construction Manual, Third Edition by the American Institute of Timber Construction (AITC). Timber falsework and formwork connections shall be designed using wet condition stresses for all installations West of the Cascade Range crest line and by criteria provided in the following sections. Frictional resistance shall not be considered as contributing to the stability of a timber connection.

6-02.3(17)I1 Bolted Connections

Tabulated values in the AITC Timber Construction Manual , Current Edition are based on square posts. For a round post or pile, the main member thickness shall be the side of a square post having the same cross-sectional area as the round post used. The AITC Table 6.20 for Douglas Fir-Larch bolt Group 3 and for Hem-Fir bolt Group 8 show design values for bolts to be used when the load is applied either parallel or perpendicular to the direction of the wood grain. When the load is applied at an angle to the grain, as is the case with falsework bracing, the design value for the main member shall be obtained from the Hankinson formula shown in the AITC manual. Design values in the AITC Table 6.20 apply only to three-member joints (bolt in double- shear) in which the side members are each ½ the thickness of the main member. This joint configuration is not typical of bridge falsework where side members are usually much smaller than main members. For two-member joints (single shear bolt condition), the AITC Table 6.20 values shall be adjusted by a single shear load factor as follows:

6-02.3(17)I2 Lag Screw Connections

Design values for lag screws subject to withdrawal loading are found in AITC Table 6.27. Values for wood having a specific gravity of 0.51 for Douglas Fir-Larch or 0.42 for Hem-Fir shall be assumed when using the table. The withdrawal values are in pounds per inch of penetration of the threaded part of the lag screw into the side grain of the member holding the point, with the axis of the screw perpendicular to that member. The maximum load on a given screw shall not exceed the allowable tensile strength of the screw at the root section. AITC recommends against subjecting lag screws to end-grain withdrawal loading. However, if this condition cannot be avoided, the design value shall be 75 percent of the corresponding value for withdrawal from the side grain. Values in the Group II wood species column shall be used for Douglas Fir-Larch and the Group III wood species column shall be used for Hem-Fir. When the load is applied at an angle to the grain, as is the case with falsework bracing, the design value shall be obtained from the Hankinson formula shown in the AITC manual. When lag screws are subjected to a combined lateral and withdrawal loading, as would be the case with longitudinal bracing when the falsework bents are skewed, the effect of the lateral and withdrawal forces shall be determined separately. The withdrawal component of the applied load shall not exceed the allowable value in withdrawal. The lateral component of the applied load shall not exceed the allowable lateral load value. Lag screws shall be inserted in lead holes as follows:

6-02 Concrete Structures4. To facilitate insertion, soap or other lubricant shall be used on the screws or in the

lead hole.

6-02.3(17)I3 Drift Pin and Drift Bolt Connections

When drift pins or drift bolts are used, the required length and penetration shall be determined using the following criteria. The lateral load-carrying capacity of drift pins and drift bolts driven into the side grain of a wood member shall be limited to 75 percent of the design values for a common bolt of the same diameter and length in the main member. For drift pin connections, the pin penetration into the connected members shall be increased to compensate for the absence of a bolt head and nut. For drift bolts or pins driven into the end grain of a member, the lateral load-carrying capacity shall be limited to 60 percent of the allowable side grain load (perpendicular to grain value) for an equal diameter bolt with nut. To develop this allowable load the drift bolt or pin shall penetrate at least 12 diameters into the end grain. To fully develop the allowable load of the drift bolts or pins, they shall be driven into predrilled holes, 1/16 inch less in diameter than the drift pin or bolt diameter. The criteria shown in the AITC Timber Construction Manual, Current Edition shall apply to drift bolt or pin connection allowable loads for the following conditions:

6-02.3(17)I4 Nailed and Spiked Joints

Joints using nails or spikes shall conform to the provisions of AITC. For side grain withdrawal, the values in AITC Table 6.35 for wood having a specific gravity of 0.51 for Douglas Fir-Larch and a specific gravity of 0.42 for Hem-Fir shall be used. End grain withdrawal shall not be used. For lateral loading, the values in AITC Table 6.36 for wood species Group II for Douglas Fir-Larch and wood species Group III for Hem-Fir shall be used. Diameters listed in the tables apply to fasteners before application of protective coatings. When more than one nail or spike is used in a joint, the total design value for the joint in withdrawal or lateral resistance shall be the sum of the design values for the individual nails or spikes. The tabulated design values for lateral loads are valid only when the nail penetrates into the main member at least 11 diameters for Douglas Fir-Larch and 13 diameters for Hem- Fir. Note that the values are maximum values for the type and size of fastener shown. The tabulated values shall not be increased even if the actual penetration is exceeded. When main member penetration is less than 11 diameters for Douglas Fir-Larch and 13 diameters for Hem-Fir, the design value shall be determined by straight-line interpolation between zero and the tabulated load, except that penetration shall not be less than ⅓ of that specified. Double-headed or duplex nails used in falsework and formwork construction are shorter than common wire nails or box nails of the same size designation. They have less penetration into the main member and therefore their load-carrying capacity shall be adjusted accordingly. Nail and spike minimum spacing in timber connections shall be as follows:

6-02.3(17)I5 Timber Connection Adjustment for Duration of Load

Tabulated values for timber fasteners are for normal duration of load and may be increased for short duration loading, except for connections used in falsework and formwork for post tensioned Structures and staged construction sequences. Duration of load adjustment for timber connections shall not be allowed for all post tensioned Structures and for staged construction sequences where delayed and/or staged loading occurs for any type of concrete Structure. The adjustment for duration of load as described in this section applies only to design values for timber connectors, such as nails, bolts, and lag screws. Allowable stresses for timber and structural steel components used in the connection, as described in Section 6-02.3(17)B , are maximums and thus shall not be increased. Tabulated values for nails, bolts, and lag screws may be adjusted by the following duration-of-load factors:

6-02.3(17)J Face Lumber, Studs, Wales, and Metal Forms

Elements of this section shall be designed for the loads, allowable stresses, deflections, and conditions which pertain from other Subsections of Section 6-02.3(17) . Forms battered or inclined above the concrete will tend to lift up as concrete is placed and shall have positive anchorage or counterweights designed to resist uplift and shall be shown in the formwork plans. Where the concrete pouring sequence causes fresh concrete to be significantly higher along one side of tied forms than the opposite side, a positive form anchorage system shall be designed capable of resisting the imbalance of horizontal thrust, and prevent the dislocation and sliding of the entire form unit. Wooden forms shall be faced with smooth sanded, exterior plywood. This plywood shall meet the requirements of the National Bureau of Standards, U.S. Product Standard PS 1, and the design specification of the American Plywood Association (APA). Each full sheet shall bear the APA stamp. The Contractor shall list in the form plans the grade and class of plywood. If the Engineer accepts the manufacturer’s certification of structural properties, the Contractor may use plywood that does not carry the APA stamp. Plywood panels stamped “shop” or “shop cutting”, shall not be used. Plyform is an APA plywood specifically designed and manufactured for concrete forming. Plyform differs from conventional exterior plywood grades in strength and the exterior face panels are sanded smooth and factory oiled. Likewise, there is a significant difference between grades designated Class 1, Class 2, and Structural I Plyform. Page 6-86 M 41-10

6-02 Concrete StructuresThe grades of plywood for various form applications shall be as follows:

6-02.3(17)K Concrete Forms on Steel Spans

Concrete forms on all steel Structures shall be removable and shall not remain in place. Where needed, the forms shall have openings for truss or girder members. Each opening shall be large enough to leave at least 1½ inches between the concrete and steel on all sides of the steel member after the forms have been removed. Unit Contract prices cover all costs related to these openings. The Contractor shall not weld any part of the form to steel members. Page 6-88 M 41-10

6-02 Concrete StructuresThe compression member or bottom connection of cantilever formwork support brackets

shall bear either within 6 inches maximum vertically of the bottom flange or within 6 inches maximum horizontally of a vertical web stiffener. The Contractor’s bridge deck form system shall be designed to prevent rotation of the steel girder. This can be achieved by temporary struts and ties or other methods the Contractor shows to be effective. Partial depth cantilever formwork support brackets that do not conform to the above requirements shall not be used unless the Contractor submits Type 2E Working Drawings consisting of details showing the additional formwork struts and ties used to brace the steel girder against web distortion caused by the partial depth bracket. If the Engineer permits bolt holes in the web to support form brackets, the holes shall be shop drilled unless otherwise allowed by the Engineer. The Contractor shall fill the holes with fully torqued ASTM F3125 Grade A325 bolts in accordance with Section 6-03.3(33) . Each bolt head shall be placed on the exterior side of the web. There shall be no holes made in the flanges.

6-02.3(17)L Finishing Machine Support System

Before using finishing machines, the Contractor shall submit a Type 2 Working Drawing consisting of detailed drawings that show the system proposed to support it. The Contractor shall not attach this (or any other) equipment support system to the sides or suspend it from any girder unless the Engineer permits. The Engineer will not permit such a method if it will unduly alter stress patterns or create too much stress in the girder.

6-02.3(17)M Restricted Overhead Clearance Sign

6-02.3(17)M1 Vehicular Traffic

The Contractor shall notify the Engineer not less than 15 working days before the anticipated start of each falsework and girder erection operation whenever such falsework or girders will reduce clearances available to the public traffic. Falsework openings shall not be more restrictive to traffic than shown in the Contract Plans. Where the height of vehicular openings through falsework is less than 15 feet, a W 12-2 “Low Clearance Symbol Sign” shall be erected on the Shoulder in advance of the falsework and two or more W 12-301 and/or W 12-302 signs shall be attached to the falsework to provide accurate usable clearance information over the entire falsework opening. The posted low clearance shall include an allowance for anticipated falsework girder deflection (rounded-up to the next whole inch) due to design dead load, including all successive concrete pours. W 12-302 signs shall be used to designate prominent clearance restrictions and limits of usable clearance. In addition, where the clearance is less than the legal height limit (14 feet), a W 12-2 sign shall be erected in advance of the nearest intersecting road or wide point in the road at which a vehicle can detour or turn around. A W 13-501 sign indicating the distance to the low clearance shall be installed below the advance sign. The Engineer will furnish the above noted signs and the Contractor shall erect and maintain them, all in accordance with Section 1-10.3(3) .

6-02.3(17)M2 Railroad Traffic

When erecting falsework that restricts overhead clearance above a railroad track, the Contractor shall place restricted overhead clearance signs in accordance with the railroad requirements. Unit Contract prices cover all costs relating to these signs.

6-02.3(17)N Removal of Falsework and Forms

The Contractor may request to remove forms based on the criteria in the table below. Both compressive strength and minimum time criteria shall be met if both are listed in the applicable row. The minimum time shall be from the time of the last concrete placement in the forms. In no case shall the Contractor remove forms or falsework without the Engineer’s concurrence. M 41-10 Page 6-89 Concrete Structures 6-02Concrete Placed InPercent of Specified Minimum Compressive Strength1Minimum Compressive Strength1Minimum Time Side forms not supporting the concrete weight, including columns, walls, crossbeams, nonsloping box girder webs, abutments, and traffic and pedestrian barriers.3 days or 1,400 psi 18 hours Side forms of footings, pile caps, and shaft caps.218 hours Crossbeams, sloping box girder webs, struts, inclined columns, inclined walls, and other forms that support the concrete weight.80 5 days Bridge decks supported on stringers, beam, or girders.380 14 days Box girders, T-beam girders, and flat-slab Superstructure.380 14 days Arches380 21 days 1Strength shall be proved by test cylinders made from the last concrete placed into the form. The cylinders shall be cured according to FOP for AASHTO R 100. 2Curing compound shall be immediately applied to the sides when forms are removed. 3Where continuous spans or segments are involved, the time for all spans will be determined by the last concrete placed affecting any span. Before releasing supports from beneath beams and girders, the Contractor shall remove forms from columns to enable the Engineer to inspect the column concrete. Curing shall comply with the requirements of Section 6-02.3(11) . The concrete surface shall not become dry during form removal if removed during the cure period. Before placing forms for traffic and pedestrian barriers, the Contractor shall completely release all falsework under spans. The Engineer may allow leaving in place forms for footings in cofferdams or cribs. This decision will be based on whether removing them would harm the cofferdam or crib and whether the forms will show in the finished Structure. All cells of a box girder Structure which have permanent access shall have all forms completely removed, including the bridge deck forms. All debris and all projections into the cells shall be removed. Unless otherwise shown in the Plans, the bridge deck interior forms in all other cells where no permanent access is available, may be left in place. Falsework and forms supporting sloping exterior webs shall not be released until the bridge deck and deck overhang concrete has obtained its removal strength and number of days criteria listed in the table above. Stem reshoring shall not be used. Open joints shown in the Plans shall have all forms completely removed, including Styrofoam products and form anchors, allowing the completed Structure to move freely. If the Contractor intends to support or suspend falsework and formwork from the bridge Structure while the falsework and formwork is being removed, the Contractor shall submit a Type 2 Working Drawing consisting of the falsework and formwork removal plan and calculations. The falsework and formwork removal plan shall include the following:

6-02 Concrete Structures2. The location, capacity, and size of all attachments, beams, cables, and other hardware

used to attach to the Structure or support the falsework and formwork;

6-02.3(17)O Early Concrete Test Cylinder Breaks

The fabrication, curing, and testing of the early cylinders shall be the responsibility of the Contractor. Early cylinders are defined as all cylinders tested in advance of the design age of 28 days whose purpose is to determine the in-place strength of concrete in a Structure prior to applying loads or stresses. The Contractor shall retain a testing Laboratory to perform this Work. Testing Laboratories’ equipment shall be calibrated within 1 year prior to testing and testers shall be either ACI certified or qualified in accordance with AASHTO R 18. The concrete cylinders shall be molded in accordance with FOP for AASHTO R 100 from concrete last placed in the forms and representative of the quality of concrete placed in that pour. The cylinders shall be cured in the field in accordance with FOP for AASHTO R 100 Section 10.2 Field Curing. The concrete cylinders shall be tested for compressive strength in accordance with AASHTO T 22. The number of early cylinder breaks shall be in accordance with the Contractor’s need and as allowed by the Engineer. The Contractor shall submit a Type 2 Working Drawing consisting of all test results, proof of equipment calibration, and tester’s certification. The Contractor shall not remove forms without the concurrence of the Engineer. All costs in connection with furnishing cylinder molds, fabrication, curing, and testing of early cylinders shall be included in the unit Contract prices for the various Bid items of Work involved.

6-02.3(18) Placing Anchor Bolts

The Contractor shall comply with the following requirements in setting anchor bolts in piers, abutments, or pedestals:

6-02.3(18)A Resin Bonded Anchors

The resin bonded anchor system shall include the nut, washer, and threaded anchor rod which is installed into hardened concrete with a resin bonding material. M 41-10 Page 6-91 Concrete Structures 6-02Resin bonding material used in overhead and horizontal application shall be specifically recommended by the resin manufacturer for those applications. Resin bonding material used in submerged liquid environment shall be specifically recommended by the resin manufacturer for this application. Threaded anchor rod and nuts, resin bonding material, embedment depth and ultimate anchor tensile capacity requirements are specified in Section 9-06.4 . The Contractor shall submit items 1 and 2 below to the Engineer for all resin bonded anchor systems. If the resin bonded anchor system and anchor diameter are not listed in the current WSDOT Qualified Products List, the Contractor shall submit items 1, 2 and 3 with the RAM in accordance with Section 1-06.1(2). For resin bonded anchor systems that are installed in a submerged liquid environment the Contractor shall submit items 1, 2, and 4 below. If the resin bonded anchor system and anchor diameter are not listed in the current WSDOT Qualified Products List, the Contractor shall submit items 1, 2, 3, and 4 with the RAM in accordance with Section 1-06.1(2).

6-02 Concrete StructuresWhen the anchor embedment depth in the Plans is less than the minimum values

specified in Section 9-06.4 , the anchor nuts shall be tightened to the torque values specified in the Plans, or as recommended by the resin bonded anchor system manufacturer and approved by the Engineer.

6-02.3(19) Bridge Bearings

Bridge bearings include the following:

6-02.3(19)A Design Requirements for HLMR Bearing Assemblies

The Contractor shall design HLMR bearing assemblies based on the AASHTO LRFD Bridge Design Specifications and the following:

6-02.3(19)B Submittals

6-02.3(19)B1 HLMR Bearing Design Calculations Submittal

The Contractor shall submit Type 2E Working Drawings consisting of design calculations for all HLMR bearing components, including the polyether urethane disc, shear pin, base plates, bearing plates, sole plates, masonry plates, guide bars, keeper plates and bars, and anchor bolts. The submittal shall include, at a minimum, the following:

6-02.3(19)B2 HLMR Bearing Manufacturer Experience Submittal

The Contractor shall submit a Type 1 Working Drawing consisting of the name of the HLMR bearing manufacturer with a certification of HLMR bearing manufacturing experience. The certification of experience shall include a list of at least five HLMR bearing Installations performed by the bearing manufacturer on previous projects. The list shall include the following Information at a minimum for each installation:

6-02.3(19)B3 Fabrication Shop Drawing Submittal

The Contractor shall submit Type 2 Working Drawings consisting of bearing fabrication shop drawings, including, at a minimum, the following:

6-02 Concrete Structures8. All AASHTO, ASTM and other material designations.

6-02.3(19)B4 Submittals of Acceptance Test Reports and Certificates

The Contractor shall submit the following production samples and test reports and certificates for fabricated bridge bearing assemblies as applicable:

6-02.3(19)B5 Quality Assurance and Final Shop Inspection Process Submittal

The Contractor shall submit a Type 1 Working Drawing consisting of the independent inspection entity performing the Quality Assurance Inspection and Final Shop Inspection as specified in Section 6-02.3(19)F . The submittal shall include, at a minimum, the name, address, phone number, and contact person of the inspection entity performing the Inspection, the proposed Quality Assurance Inspection Program, and the forms to be used for the Quality Assurance Inspection Program.

6-02.3(19)B6 HLMR Bearing Testing Procedure Submittal

The Contractor shall submit a Type 1 Working Drawing consisting of the name, address, phone number, and contact person of the testing entity performing the required bearing testing specified in Section 6-02.3(19)E . The testing entity shall be one of the following:

6-02.3(19)B7 HLMR Bearing Assembly Inspection Reports and Certificates

The Contractor shall submit Type 1 Working Drawings consisting of the periodic inspection reports of the independent inspection entity performing the required certified shop inspection, at a frequency defined in the Quality Assurance Inspection Program of Sections 6-02.3(19)B5 and 6-02.3(19)F2 . The daily inspection reports shall report on the shop fabrication and testing activities relating to the bearing assemblies, and their conformance to the specification requirements. The Contractor shall submit written documentation from the bearing manufacturer and the independent inspection entity certifying that the bearing assemblies have been manufactured in full compliance with the specification requirements. M 41-10 Page 6-95 Concrete Structures 6-026-02.3(19)C Bearing Assembly Fabrication The edges of all components shall be broken by grinding so that there are no sharp edges.

6-02.3(19)C1 Flatness and Manufacturing Tolerances

Flatness of bearing surfaces shall be determined by the following method:

6-02 Concrete StructuresStainless Steel Sheet

Plan dimension: - 0, + 3/16-inch Flatness: Class A tolerance, both surfaces Backing, Bearing, Masonry, Sliding, and Sole Plates of HLMR Bearings Plan dimensions Greater than 30-inches: - 0, + 3/16-inch 30-inches or less: - 0, + 1/8-inch Thickness: - 1/32, + 1/8-inch Flatness: Class A tolerance, side in contact with steel, polyether urethane disc, or PTFE Class C tolerance, side in contact with epoxy gel or grout or concrete Width and length of PFTE recess: - 0, + 0.04-inch of PTFE sheet size The maximum gap between the external restrainer and the circular base plate, and the walls of a recess and a recessed plate, for a spherical bearing shall be 0.04-inches. Backing, Masonry, and Sole Plates of Pin, Fabric Pad, and Transverse Stop Bearings Plan dimensions: - 0, + 3/16-inch Thickness: - 0, + 3/16-inch Flatness: Class A tolerance, side in contact with stainless steel sheet, sole plate and pre- formed fabric pad Class C tolerance, side in contact with epoxy gel or grout or concrete Width and length of PTFE recess: - 0, + 1/16-inch of PTFE sheet size The maximum gap between the external restrainer and the circular base plate, and the walls of a recess and a recessed plate, for a spherical bearing shall be 0.04-inches. Guide Bar and Keeper Bar Length: ± 1/8 inch Section Dimensions: ± 1/16-inch Flatness: Class A tolerance, side in contact with steel or PTFE Bar to bar tolerance: ± 1/32-inch Bars shall not be more than 1/32-inch out of parallel Bearing Block Plan dimensions: - 0, + 1/8 inch Thickness: ± 0.015-inch Groove radius for pin: As shown in the Plans M 41-10 Page 6-97 Concrete Structures 6-02Keeper ring grooves in bearing block Radius, inner and outer: ± 0.005-inch Depth of groove: ± 0.010-inch Keeper Ring Radius, inner and outer: ± 0.010-inch Thickness: ± 0.030-inch Pin Length, shldr to shldr: -0.020, + 0-inch Diameter: As shown in the Plans Overall Height HLMR bearing: - 1/16, + 3/16-inch Fabric pad bearing: - 1/16, + 3/16-inch Pin bearing: - 0, + 10-percent

6-02.3(19)C2 HLMR Bearing Specific Fabrication Requirements

All bolted connections between structural steel surfaces shall meet the maximum spacing for sealing bolts in accordance with the AASHTO LRFD Bridge Design Specifications. When the following components are shown in the Plans as part of the HLMR bearing assembly, the following specific fabrication requirements shall apply:

6-02 Concrete Structuresd. The curved surfaces of spherical bearings that receive stainless steel shall be

weld overlaid to produce a surface chemistry equivalent to ASTM A240 Type 304L or 316L stainless steel as shown in the Plans.

6-02.3(19)C3 Non-HLMR Bearing Specific Fabrication Requirements

When the following components are shown in the Plans as part of the fabric pad bearing, pin bearing, or transverse stop bearing assembly, the following specific fabrication requirements shall apply:

6-02.3(19)E HLMR Bearing Testing

The Contractor shall provide for HLMR bearing testing. The testing shall be performed by the testing entity selected in accordance with Section 6-02.3(19)B6 . All testing performed by the bearing manufacturer shall be witnessed by the inspection entity performing the certified shop inspection of the bearings. Failure of the test bearing will result in rejection of all bearings. The testing requirements specified below may be waived provided:

6-02 Concrete StructuresThe test bearing may be used as a production bearing provided:

6-02.3(19)E1 Disc Bearing Proof Load Testing

When fabrication of disc bearings is complete, a Proof Load test shall be performed either on disc bearing assemblies randomly selected from the production bearings, or an equal number of prototype bearings with a minimum design capacity of 400-kips. One disc bearing per lot shall be tested where one lot is defined as a maximum of 25-production bearings. The Proof Load test shall be performed on the selected test bearing assemblies as follows:

6-02.3(19)E2 Spherical Bearing Wear and Damage Characteristics Testing

When fabrication of spherical bearings is complete, a Wear and Damage Characteristics test shall be performed on spherical bearing assemblies randomly selected from the production bearings. For bearings with a design capacity in excess of 1,000-kips, prototype bearings may be used for the Wear and Damage Characteristics test. One spherical bearing per lot shall be tested where one lot is defined as a maximum of 25-production bearings. The Wear and Damage Characteristic test shall be performed on the selected test bearing assemblies as follows:

6-02.3(19)F Bearing Inspection and Acceptance

Three levels of inspection shall be satisfied before the bearings are accepted. The manufacturer shall provide for both Quality Control and Quality Assurance Inspection in accordance with Section 6-02.3(19)F1 and 6-02.3(19)F2 . The manufacturer shall provide access for the Final Shop Inspection in accordance with Section 6-02.3(19)F3 . The bearings shall satisfy each of the three levels of inspection as specified below prior to acceptance. Bearings that fail any one of the three levels of inspection shall have the deficiencies addressed in accordance with Section 1-05.7 . All proposed corrective procedures shall be submitted as a Type 2 Working Drawing. M 41-10 Page 6-101 Concrete Structures 6-026-02.3(19)F1 Quality Control Inspection During the fabrication process of all bearing assembly components and units, the manufacturer shall provide full time Quality Control Inspection to ensure that the materials and Work meet or exceed the minimum requirements of the Contract. Quality Control Inspection shall be the responsibility of the manufacturer’s quality control group, which shall be independent of the fabrication group.

6-02.3(19)F2 Quality Assurance Inspection

Quality Assurance Inspection shall be performed by the independent inspection entity performing the certified shop inspection in accordance with Section 6-02.3(19)B5 . Quality Assurance Inspection is not required to be full time inspection, but shall be done at all phases of the manufacturing process. The frequency of inspection shall be included in the Quality Assurance Inspection Program.

6-02.3(19)F3 Final Shop Inspection

Prior to shipping the bearings to the job site, a randomly selected representative number of production bearings shall be inspected by the independent inspection entity at the manufacturer’s facility. The manufacturer shall provide a clean, dry, and enclosed area for the bearing inspection. The manufacturer shall disassemble and reassemble the bearings for inspection by the independent inspection entity. The independent inspection entity shall certify that the bearings have been inspected, and that the bearings have been manufactured in full compliance with the Contract requirements.

6-02.3(19)G Bearing Component Assembly, Shipping, and Storage

Each bearing, except bearing components welded to the bottom flange of steel girders or embedded into concrete superstructure, shall be fully assembled at the manufacturing plant and delivered to the construction site as a complete unit, ready for installation. The units shall be held together with removable restraints so that the sliding surfaces are not damaged. Softeners shall be placed under the restraints to protect all painted surfaces. The Contractor shall not damage the painted surfaces while shipping, storing and installing the bearing assemblies. All bearing assemblies shall be marked with the following information prior to shipping:

6-02.3(19)H Bearing Assembly Field Inspection

The Contracting Agency may perform field inspection of bearing assemblies at the discretion of the Engineer. The Contractor shall provide a clean, dry and enclosed area at the site, spacious enough for the field inspection activities. The Contractor shall disassemble and reassemble the bearings for inspection by the Engineer. The disassembly and reassembly of the bearings shall be in accordance with the bearing manufacturer’s written procedure and in the presence of the Engineer. Bearings that fail the field inspection shall have the deficiencies addressed in accordance with Section 1-05.7 . All proposed corrective procedures shall be submitted as a Type 2 Working Drawing. Page 6-102 M 41-10

6-02 Concrete Structures6-02.3(19)I Bearing Assembly Installation

The Contractor shall install the bearing assembly in accordance with the installation procedure included with the fabrication shop drawing submittal required by Sliding surfaces shall be finished true, lubricated, and installed level, or installed as shown in the Plans for transverse stop bearings. PTFE sheet shall not be greased, except as otherwise noted. A thin uniform film of silicone grease shall be applied to the entire dimpled PTFE sheet before installation (all dimples shall be filled with grease). For bearing assemblies with PTFE and stainless steel components, the Contractor shall take special care at all times to ensure protection of the PTFE and stainless steel surfaces from coming in contact with concrete and any other foreign matter. The grout pad, and masonry plate when shown in the Plans, shall be formed and placed in accordance with Section 6-02.3(20) , and installed level. The grout pad thickness shall be adjusted based on final bearing design dimensions, and to achieve final grade profile elevations as shown in the Plans. When shown with a masonry plate, the grout pad shall be pressure installed starting at the middle of the masonry plate. For cast-in-place concrete superstructures, the upper units of bearing assemblies shall be anchored to the superstructure as shown in the Plans. For steel and precast concrete superstructures, the uppermost unit of bearing assemblies shall be connected or anchored to the superstructure as shown in the Plans. When specified in the Plans for bearing assemblies supporting steel or precast concrete superstructure, the interface between the sole plate and the bridge superstructure (or the upper and lower sole plates when two separate components) shall be set with epoxy gel just before setting the superstructure in place. The (lower) sole plate surface in contact with the epoxy gel shall receive a thin uniform film of silicone grease, to prevent bonding to the epoxy gel. The threads of the sole plate clamping bolts shall be greased to prevent bonding and allow future removal. The Contractor shall apply the epoxy gel by troweling it onto the bottom surface of the steel girder flange or the upper sole plate welded to the steel girder flange and shall immediately bolt the (lower) sole plate in place to obtain a level surface. Before the epoxy gel has cured, the steel or precast concrete superstructure shall be set in place, squeezing out the excess epoxy gel while filling the interface between the steel surfaces. Excess epoxy and grease shall be removed immediately. After the epoxy gel has cured, the sole plate clamping bolts shall be tightened to snug tight. When the upper unit of the pin bearing consists of an upper bearing block welded to a sole plate, the top surface of the sole plate shall receive a thin uniform film of silicone grease, and the bolt threads connecting the pin assembly to the steel superstructure shall be greased, prior to fastening the sole plate to the steel superstructure. Specified surfaces of the bearing blocks, pins, and pin nuts shall be coated with grease as specified in Section 6-02.3(19)D . After installation, the orientation of the spherically curved units shall be ± 1/2 degree from level.

6-02.3(20) Grout for Anchor Bolts and Bridge Bearings

Grout shall conform to Section 9-20.3(2) for anchor bolts and for bearing assemblies with bearing plates. Grout shall conform to Section 9-20.3(3) for elastomeric bearing pads and fabric pad bearings without bearing plates. Grout shall be a workable mix with a viscosity that is suitable for the intended application. Grout shall not be placed outside of the manufacturer recommended range of thickness. The Contractor shall receive concurrence from the Engineer before using the grout. M 41-10 Page 6-103 Concrete Structures 6-02Field grout cubes and cylinders shall be fabricated and tested in accordance with Section 9-20.3 when requested by the Engineer, but not less than one per bridge pier or once per day. Before placing grout, the substrate on which it is to be placed shall be prepared as recommended by the manufacturer to ensure proper bonding. The grout shall be cured as recommended by the manufacturer. The grout may be loaded when a minimum of 4,000 psi compressive strength is attained. To grout bridge bearing masonry plates, the Contractor shall:

6-02.3(21) Drainage of Box Girder Cells

To drain box girder cells, the Contractor shall provide and install, according to details in the Plans, short lengths of nonmetallic pipe in the bottom slab at the low point of each cell. The pipe shall have a minimum inside diameter of 4 inches. If the difference in Plan elevation is 2 inches or less, the Contractor shall install pipe in each end of the box girder cell. All drainage holes shall be screened in accordance with the Plan details.

6-02.3(22) Drainage of Substructure

The Contractor shall use weep holes and gravel backfill that complies with Section

9-03.12(2) to drain fill material behind retaining walls, abutments, tunnels, and wingwalls.

To maintain thorough drainage, weep holes shall be placed as low as possible. Weep holes shall be covered with geotextile meeting the requirements of Section 9-33.2 , Table 2 Class C before backfilling. Geotextile screening shall be bonded to the concrete with an accepted adhesive. Gravel backfill shall be placed and compacted as required in Section

2-09.3(1)E In addition, if the Plans require, tiling, French or rock drains, or other drainage

devices shall be installed. If underdrains are not installed behind the wall or abutment, all backfill within 18 inches of weep holes shall comply with Section 9-03.12(4) . Unless the Plans require otherwise, all other backfill behind the wall or abutment shall be gravel backfill for walls.

6-02.3(23) Opening to Traffic

Bridges with a bridge deck made of concrete shall remain closed to all traffic, including construction equipment, until the concrete has reached the 28-day specified compressive strength. This strength shall be determined with cylinders made of the same concrete as the bridge deck and cured under the same conditions. A concrete deck bridge shall never be opened to traffic earlier than 10 days after the deck concrete was placed and never before the Engineer allows. Page 6-104 M 41-10

6-02 Concrete StructuresFor load restrictions on bridges under construction, refer to Section 6-01.6 .

After curing bridge approach slabs in accordance with Section 6-02.3(11) , the bridge approach slabs may be opened to traffic when a minimum compressive strength of 2,500 psi is achieved.

6-02.3(24) Reinforcement

Although a bar list is normally included in the Plans, the Contracting Agency does not guarantee its accuracy and it shall be used at the Contractor’s risk. Reinforcement fabrication details shall be determined from the information provided in the Plans. Before delivery of the reinforcing bars, the Contractor shall submit Type 1 Working Drawings consisting of an informational copy of the supplemental bending diagrams.

6-02.3(24)A Field Bending

Field bending of AASHTO M31 Grade 60 and ASTM A706 Grade 60 reinforcement shall be done in accordance with the requirements of this section. Field bending of all other reinforcement shall require a Type 2 Working Drawing showing the bend radii, bending and heating procedures, and all inspection or testing requirements. Field bending shall not be done on reinforcement within the top or bottom third of column lengths or within plastic hinge regions identified in the Plans. Field bending shall not be done on bar sizes No. 14 or No. 18. In field-bending steel reinforcing bars, the Contractor shall:

6-02.3(24)B Protection of Materials

The Contractor shall protect reinforcing steel from all damage. When placed into the Structure, the steel shall be free from dirt, loose rust or mill scale, paint, oil, and other foreign matter. When transporting, storing, or constructing in close proximity to bodies of salt water, plain and epoxy-coated steel reinforcing bar shall be kept in enclosures that provide protection from the elements. If plain or epoxy-coated steel reinforcing bar is exposed to mist, spray, or fog that may contain salt, it shall be flushed with fresh water prior to concrete placement. When the Engineer requires protection for reinforcing steel that will remain exposed for a length of time, the Contractor shall protect the reinforcing steel:

6-02 Concrete Structures6-02.3(24)C Placing and Fastening

The Contractor shall position reinforcing steel as the Plans require and shall ensure that the steel is set within specified tolerances. Adjustments to reinforcing details outside of specified tolerances to avoid interferences and for other purposes are acceptable when approved by the Engineer. When spacing between bars is 1 foot or more, they shall be tied at all intersections. When spacing is less than 1 foot, every other intersection shall be tied. If the Plans require bundled bars, they shall be tied together with wires at least every 6 feet. All epoxy-coated bars in the top mat of the bridge deck shall be tied at all intersections, however they may be tied at alternate intersections when spacing is less than 1 foot in each direction and they are supported by continuous supports meeting all other requirements of supports for epoxy-coated bars. Other epoxy-coated bars shall also be tied at all intersections, but shall be tied at alternate intersections when spacing is less than 1 foot in each direction. Wire used for tying epoxy-coated reinforcing steel shall be plastic coated. Tack welding is not permitted on reinforcing steel. Abrupt bends in the steel are permitted only when one steel member bends around another. Vertical stirrups shall pass around main reinforcement or be firmly attached to it. For slip-formed concrete, the reinforcing steel bars shall be tied at all intersections and cross braced to keep the cage from moving during concrete placement. Cross bracing shall be with additional reinforcing steel. Cross bracing shall be placed both longitudinally and transversely. After reinforcing steel bars are placed in a traffic or pedestrian barrier and prior to slip-form concrete placement, the Contractor shall check clearances and reinforcing steel bar placement. This check shall be accomplished by using a template or by operating the slip-form machine over the entire length of the traffic or pedestrian barrier. All clearance and reinforcing steel bar placement deficiencies shall be corrected by the Contractor before slip-form concrete placement. Precast concrete supports (or other accepted devices) shall be used to maintain the concrete coverage required by the Plans. The precast concrete supports shall:

6-02 Concrete StructuresEmbedded length of bars and length of bar lap splices:

No 3 through No. 11 -1 in. No. 14 through No. 18 -2 in. Concrete cover measured perpendicular to concrete surface (except for the top surface of bridge decks, bridge approach slabs and other roadway surfaces): ±0.25 inch Concrete cover measured perpendicular to concrete surface for the top surface of bridge decks, bridge approach slabs and other roadway surfaces: +0.25 inch, -0 inch Before placing concrete, the Contractor shall:

6-02.3(24)D Splicing

The Contractor shall supply steel reinforcing bars in the full lengths the Plans require. Unless the Engineer concurs in writing, the Contractor shall not change the number, type, or location of splices. The Engineer may permit the Contractor to use thermal or mechanical splices in place of the method shown in the Plans if they are of an accepted design. Use of a new design may be granted if:

6-02.3(24)D1 Splicing of Hoop Reinforcement for Columns and Shafts

When the Plans show steel reinforcement bar hoops, the hoops shall be spliced by one of the following methods:

6-02.3(24)F Mechanical Splices

The Contractor shall form mechanical splices with an Engineer-accepted system using sleeve filler metal, threaded coupling, or another method that complies with this section. If necessary to maintain required clearances after the splices are in place, the Contractor shall adjust, relocate, or add stirrups, ties, and bars. Before splicing, the Contractor shall provide the Engineer with the following information for each shipment of splice material:

6-02 Concrete StructuresAll splices shall meet these criteria:

6-02.3(24)G Job Control Tests

As the Work progresses, the Engineer may require the Contractor to provide a sample splice (thermal or mechanical) to be used in a job control test. The operator shall create this sample on the job site with the Engineer present using bars of the same size as those being spliced in the Work. The sample shall comply with all requirements of these Specifications and is in addition to all other sample splices required for qualification. The Engineer will require no more than two samples on a project with fewer than 200 splices and no more than one sample per 100 splices on a project with more than 200 splices. M 41-10 Page 6-111 Concrete Structures 6-026-02.3(24)H Epoxy-Coated Steel Reinforcing Bar This Work is furnishing, fabricating, coating, and placing epoxy-coated steel reinforcing bars as the Plans, these Specifications, and the Special Provisions require. Coating material shall be applied electrostatically, by spraying, or by the fluidized-bed method. All epoxy-coated bars shall comply with the requirements of Section 9-07 . Fabrication may occur before or after coating. The Contractor shall protect epoxy-coated bars from damage using padded or nonmetallic slings and straps free from dirt or grit. To prevent abrasion from bending or sagging, the Contractor shall lift bundled bars with a strong-back, multiple supports, or a platform bridge. Bundled bars shall not be dropped or dragged. During shop or field storage, bars shall rest on wooden or padded cribbing. The Contractor may substitute other methods for protecting the bars if the Engineer concurs. If the Engineer believes the coated bars have been badly damaged, they will be rejected. Metal chairs and supports shall be coated with epoxy (or another inert coating accepted by the Engineer). The Contractor may use other support devices with the Engineer’s concurrence. Plastic coated tie wires (accepted by the Engineer) shall be used to protect the coated bars from being damaged during placement. The bars shall be placed as the Plans require and held firmly in place during placing and setting of the concrete. All bars shall be placed and fastened as specified in In the interval between installing coated bars and concreting the deck, the Contractor shall protect the coating from damage that might result from other construction Work. The Engineer will inspect the coated bars after they are placed and before the deck concrete is placed. The Contractor shall patch all areas that show significant damage (as defined below). Significant damage means an opening in the coating that exposes the steel in an area that exceeds:

6-02.3(24)I Resistance Butt Weld Splicing of Hoop Reinforcement for Columns and

Shafts

6-02.3(24)I1 Splicing Quality Control Manager

The Contractor shall designate in writing a Splicing Quality Control Manager (SQCM). The SQCM shall be responsible for the quality of all hoop reinforcement splicing, including the inspection of materials and quality of Work, and submitting, receiving, and approving all correspondence, required submittals, and reports regarding hoop reinforcement splicing to and from the Engineer. Page 6-112 M 41-10

6-02 Concrete Structures6-02.3(24)I2 Splice Sample Test Facilities

Qualification testing and testing of production sample splices shall be performed at an independent qualified testing laboratory at no additional expense to the Contracting Agency. The laboratory shall have the following:

6-02.3(24)I3 Splice Qualification Report

The Contractor shall submit a Splice Qualification Report as a Type 2 Working Drawing. This report shall include, at a minimum:

6-02.3(24)I4 Production Control Splice Test Criteria

For the purpose of hoop reinforcement splice testing, a lot of splices are defined as 200, or a fraction thereof, of the same type of splice for each bar diameter that is used in the work. A production control sample shall consist of four splices removed from each lot of completed splices. The Contractor shall select the splices comprising the lot. The Engineer will, or the SQCM shall if the Engineer is not available, select the product control sample of four splices to be tested from each lot. Production control testing shall be performed for all hoop reinforcement splices used in the work. Production control samples shall be tested in accordance with ASTM A370. M 41-10 Page 6-113 Concrete Structures 6-026-02.3(24)I5 Sample Test Criteria After the splices in a lot have been completed, the SQCM shall notify the Engineer in writing that the splices in this lot conform to the specifications and are ready for testing. At least one week before sample testing, the Contractor shall notify the Engineer by a Type 1 Working Drawing of the date and location of the testing to allow the Engineer the opportunity to witness the testing. Samples shall achieve at least 125 percent of the specified yield strength of the bar. In addition, either necking of the bar or a plateau of the stress-strain curve shall be evident at rupture.

6-02.3(24)I6 Sample Acceptance Criteria

If all four sample splices from a lot conform to the requirements of Section 6-02.3(24)I5 , all splices in the lot represented by the test will be considered acceptable. If only two or three of the four sample splices from a lot conform to the requirements of Section 6-02.3(24)I5 , the Engineer will, or the SQCM shall if the Engineer is not available, select an additional set of four samples for re-test from the same lot of splices. Should any of the four sample splices from this additional test fail to conform to these requirements; all splices in the lot will be rejected. Should only one sample splice from a lot conform to the requirements of Whenever a lot of splices are rejected, the rejected lot and subsequent lots of splices shall not be used in the work until the following requirements are met:

6-02.3(24)I7 Reporting Test Results

A Production Control Test Report for all testing performed on each lot shall be prepared by the independent testing laboratory performing the testing and submitted to the SQCM. The report shall include the following information for each test:

6-02 Concrete StructuresThe SQCM shall review, approve with a signature, and submit each Production Control

Test Report as a Type 2 Working Drawing. The Contractor shall not encase the splices represented by the report in concrete until receiving the Engineer’s written response to the submittal.

6-02.3(24)J Welded Direct Butt Splicing of Hoop Reinforcement for Columns and

Shafts

6-02.3(24)J1 Splicing Quality Control Manager

The Contractor shall designate a Splicing Quality Control Manager (SQCM) responsible for the quality control of all hoop reinforcement splicing. The SQCM shall be responsible for preparing all required submittals and reports regarding hoop reinforcement splicing. Prior to performing any production hoop splicing Work, the Contractor shall submit a Hoop Splicing Quality Control Plan as a Type 2 Working drawing, which shall include the following:

6-02.3(24)J2 Welded Direct Butt Splices

Welded direct butt splices shall be complete joint penetration butt welds conforming to ANSI/AWS D1.4/D1.4M:2018 figure 5.2. Split pipe backing shall not be used. Thermite welding is not allowed.

6-02.3(24)J3 Nondestructive Splice Tests

All splices, including joint geometry and fit-up, in process welding, and completed welds shall be 100 percent visually inspected by the CWI(s) accepted in the hoop Splicing Quality Control Plan. The SQCM shall submit a Type 1 Working Drawing with results of all visual inspections. Radiographic examinations shall be performed on 25 percent of all complete joint penetration butt welded splices from a lot defined as 200, or a fraction thereof, of the same type of splice for each bar diameter that is used in the work. The Contractor shall notify the Engineer in writing a minimum of 48 hours before performing radiographic examinations. All required radiographic examinations shall be performed by the Contractor in accordance with ANSI/AWS D1.4/D1.4M:2018 and as specified below. Before radiographic examination, welds shall conform to ANSI/AWS D1.4/D1.4M Section 6.4. Radiographic acceptance shall be in accordance with ANSI/AWS D1.4/D1.4M Table 6.1. Acceptance criteria for bar size #7 shall be the same as for bar size #8. Should more than 12 percent of the splices which have been radiographically examined in any lot be defective, an additional 25 percent of the splices from the same lot, selected by the Engineer, or by the SQCM if the Engineer is not available, shall be radiographically M 41-10 Page 6-115 Concrete Structures 6-02examined. Should more than 12 percent of the cumulative total of splices tested from the same lot be defective, all remaining splices in the lot shall be radiographically examined. All defects shall be repaired in accordance with ANSI/AWS D1.4/D1.4M, latest edition. The Contractor shall notify the Engineer in writing a minimum of 48 hours before performing any radiographic examinations. The radiographic procedure used shall conform to ANSI/AWS D1.1, ANSI/AWS D1.4/ D1.4M:2018 Section 9.9, and the following:

6-02 Concrete Structures11. Radiographs shall be free of film artifacts and processing defects, including, but

not limited to, streaks, scratches, pressure marks or marks made for the purpose of identifying film or welding indications.

6-02.3(24)K Welded Lap Splicing of Hoop Reinforcement for Shafts

All production splices shall be 100 percent visually inspected for weld quality, size and length. M 41-10 Page 6-117 Concrete Structures 6-026-02.3(25) Prestressed Concrete Girders Precast concrete girders shall be constructed in accordance with Section 6-02.3(9) , except as modified in this section. The manufacturing facility of prestressed concrete girders shall be certified by the Precast/Prestressed Concrete Institute’s Plant Certification Program for the type of prestressed member to be produced and shall be approved by WSDOT as a Certified Prestress Concrete Fabricator prior to the start of production. WSDOT certification will be granted at, and renewed during, the annual prestressed plant review and approval process in accordance with WSDOT Materials Manual M 46-01.04 Standard Practice QC 6. The Contracting Agency intends to perform Quality Assurance Inspection. By its inspection, the Contracting Agency intends only to facilitate the Work and verify the quality of that Work. This inspection shall not relieve the Contractor of the responsibility for identifying and replacing defective material or Work. The various types of prestressed concrete girders are: Prestressed Concrete I Girder – Refers to a prestressed concrete girder with a flanged I shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series W42G, W50G, W58G, and W74G. Prestressed Concrete Wide Flange I Girder – Refers to a prestressed concrete girder with an I shaped cross section with wide top and bottom flanges, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series WF36G, WF42G, WF50G, WF58G, WF66G, WF74G, WF83G, WF95G, and WF100G. Prestressed Concrete Wide Flange Deck Girder – Refers to a prestressed concrete wide flange I girder with extended top flange widths designed to support traffic loads, and designed to be mechanically connected at the flange edges to adjacent girders at the job site. WSDOT standard girders in this category include Series WF39DG, WF45DG, WF53DG, WF61DG, WF69DG, WF77DG, WF86DG, WF98DG, and WF103DG. Prestressed Concrete Wide Flange Thin Deck Girder – Refers to a prestressed concrete wide flange I girder with extended top flange widths requiring a cast-in-place concrete deck to support traffic loads. Flange edges extend to flange edges of adjacent girders at the job site. WSDOT standard girders in this category include Series WF36TDG, WF42TDG, WF50TDG, WF58TDG, WF66TDG, WF74TDG, WF83TDG, WF95TDG, and WF100TDG. Prestressed Concrete Deck Bulb Tee Girder – Refers to a prestressed concrete girder with a top flange designed to support traffic loads, and designed to be mechanically connected at the flange edges to adjacent girders at the job site. WSDOT standard girders in this category include Series W35DG, W41DG, W53DG, and W65DG. Prestressed Concrete Slab Girder – Refers to a prestressed concrete slab girder, with or without voids. Prestressed concrete ribbed section girders and prestressed concrete double tee girders shall conform to the requirements specified for prestressed concrete slab girders. Prestressed Concrete Tub Girder – Refers to prestressed concrete tub girders with a U shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. WSDOT standard girders in this category include Series U**G* or Series UF**G*, where U specifies webs without top flanges, UF specifies webs with top flanges, ** specifies the girder height in inches, and * specifies the bottom flange width in feet. Spliced Prestressed Concrete Girder – Refers to prestressed concrete girders initially fabricated in segments which are longitudinally spliced together with cast-in-place concrete closures and post tensioning. Post tensioning materials and construction shall Page 6-118 M 41-10

6-02 Concrete Structuresconform to Section 6-02.3(26) , except that ducts for prestressed concrete wide flange

I girders may be 24-gage, semi-rigid, galvanized, corrugated, ferrous metal. WSDOT prestressed concrete wide flange I girders in this category include Series WF74PTG, WF83PTG, WF95PTG, and WF100PTG. WSDOT prestressed concrete tub girders in this category include Series U**PTG* and UF**PTG* where U, UF, **, and * are as defined for prestressed concrete tub girders.

6-02.3(25)A Shop Drawings

Shop drawings for prestressed concrete girders shall be submitted as Type 2 Working Drawings. The only deviations to the Plans that will be permitted are those approved by the annual plant approval process and those listed below:

6-02.3(26)A The Working Drawings for spliced prestressed concrete girders shall

include all details related to the post-tensioning operations in the field, including details of hardware required, tendon geometry, blockout details, and details of additional or modified steel reinforcing bars required in cast-in-place closures.

6-02.3(25)B Prestressing

Each stressing system shall have a pressure gauge or load cell that will measure jacking force. The gauge shall display pressure accurately and readably with a dial at least 6 inches in diameter or with a digital display. Each jack and its gauge shall be calibrated as a unit and shall be accompanied by a certified calibration chart. The Contractor shall submit a Type 1 Working Drawing consisting of one copy of this chart. The cylinder extension during calibration shall be in approximately the position it will occupy at final jacking force. Jacks and gauges shall be recalibrated and recertified:

6-02.3(26) and the following requirements:

6-02 Concrete Structures2. The Contractor shall not tension the post-tensioning reinforcement until the concrete

in the cast-in-place closures reaches the minimum compressive strength specified in the Plans. This strength shall be measured with concrete cylinders made of the same concrete and cured under the same conditions as the cast-in-place closures.

6-02.3(25)C Casting

Side forms shall be steel except that cast-in-place concrete closure forms for spliced prestressed concrete girders, interior forms of prestressed concrete tub girders, and end bulkhead forms of prestressed concrete girders may be wood. Interior voids for prestressed concrete slab girders with voids shall be formed by either wax soaked cardboard or expanded polystyrene forms. The interior void forms shall be secured in the position as shown in the Working Drawings, and shall remain in place. All concrete mixes to be used shall be preapproved in the WSDOT plant certification process. The temperature of the concrete when placed shall be between 50°F and 90°F. Slump shall not exceed 4 inches for normal concrete nor 7 inches with the use of a high range water-reducing admixture, nor 9 inches when both a high range water-reducing admixture is used and the water/cement ratio is less than or equal to 0.35. For self- consolidating concrete (SCC), the slump requirements specified above do not apply, and are instead replaced by the target slump flow and slump flow range specified as part of the SCC mix design. Air-entrainment is not required in the concrete placed into prestressed concrete girders, cast-in-place concrete closures for spliced prestressed concrete girders, and prestressed concrete partial-depth stay-in-place panels, provided that the water/cement ratio is less than or equal to 0.45.

6-02.3(25)C1 Acceptance Testing of Concrete for Prestressed Concrete Girders

Compressive strength cylinders and concrete acceptance testing shall be performed once per prestressed concrete girder or once per fabrication line of prestressed concrete girders. Concrete shall not be placed until fresh concrete testing indicates concrete is within acceptable limits. Acceptance testing shall be performed by the Contractor and test results shall be submitted to the Engineer. Unless otherwise noted below, the test methods described in Section 6-02.3(5)D shall be followed. Concrete compressive strength shall be in accordance with Section 6-02.3(25)E . Concrete that is not self-consolidating concrete will be accepted as follows:

6-02.3(25)E Contractors Control Strength

Concrete strength shall be measured on test cylinders cast from the same concrete as that in the girder. These cylinders shall be cured under time-temperature relationships and conditions that simulate those of the girder. If the forms are heated by steam or hot air, test cylinders will remain in the coolest zone throughout curing. If forms are heated another way, the Contractor shall provide a record of the curing time-temperature relationship for the cylinders for each girder to the Engineer. When two or more girders are cast in a continuous line and in a continuous pour, a single set of test cylinders may represent all girders provided the Contractor demonstrates uniformity of casting and curing to the satisfaction of the Engineer. The Contractor shall mold, cure, and test enough of these cylinders to satisfy Specification requirements for measuring concrete strength. The Contractor may use 4- by 8-inch or 6- by 12-inch cylinders. Test cylinders may be cured in a moist room or water tank in accordance with FOP for AASHTO R 100 after the girder concrete has obtained the required release strength. If, however, the Contractor intends to ship the girder prior to the standard 28-day strength test, the design strength for shipping shall be determined from cylinders placed with the girder and cured under the same conditions as the girder. These cylinders may be placed in an unninsulated, moisture-proof envelope. Page 6-122 M 41-10

6-02 Concrete StructuresTo measure concrete strength in the girder, the Contractor shall randomly select two test

cylinders. The average compressive strength of the two cylinders shall be equal or greater than the specified strength and neither cylinder shall have a compressive strength that is more than 5 percent below the specified strength. If too few cylinders were molded to carry out all required tests on the girder, the Contractor shall sample and test cores from the girder under the surveillance of the Engineer. Cores sampled from one girder may not be used to represent any other girder, regardless of whether the girders were cast in a continuous line or pour. Cores shall avoid all prestressing strands, steel reinforcing bars and interior voids. For prestressed concrete slab girders, a test shall consist of four cores measuring 3 inches in diameter by 6 inches in length (for slabs) or by the thickness of the web (for ribbed and double tee sections). Two cores shall be taken from each side of the girder with one on each side of the girder span midpoint, at locations accepted by the Engineer. The core locations for prestressed concrete ribbed and double tee sections shall be immediately beneath the top flange. For prestressed concrete tub girders, a test shall consist of four cores measuring 3 inches in diameter by the thickness of the web. Two cores shall be taken from each web approximately 3 feet to the left and to the right of the center of the girder span. For all other prestressed concrete girders, a test shall consist of three cores measuring 3 inches in diameter by the thickness of the web and shall be removed from just below the top flange; one at the midpoint of the girder’s length and the other two approximately 3 feet to the left and approximately 3 feet to the right. The cores shall be taken in accordance with AASHTO T 24 and shall be tested in accordance with AASHTO T 22. The Engineer may accept the girder if the average compressive strength of the all test cores from the girder are at least 85 percent of the specified compressive strength with no one core less than 75 percent of specified compressive strength. If there are more than four cored holes in a girder, the prestressing reinforcement shall not be released until the holes are patched and the patch material has attained a minimum compressive strength equal to the required release compressive strength. All cored holes shall be patched and cured prior to shipment of the girder. The girder shall not be shipped until tests show the patch material has attained a minimum compressive strength of 4,000 psi. If the annual plant approval includes procedures for patching cored holes, the cored holes shall be patched in accordance with this procedure. Otherwise, the Contractor shall submit a core hole patching procedure as a Type 2 Working Drawing.

6-02.3(25)F Prestress Release

Side and flange forms that restrain deflection shall be removed before release of the prestressing reinforcement. All strands shall be released in a way that will minimize eccentricity of the prestressing force about the centerline of the girder. This release shall not occur until tests show each girder has reached the minimum compressive strength required by the Plans. The Contractor may request permission to release the prestressing reinforcement at a minimum concrete compressive strength less than specified in the Plans. This request shall be submitted as a Type 2E Working Drawing analyzing changes in vertical deflection, girder lateral stability and concrete stresses in accordance with Section 6-02.3(25)L2 .

6-02.3(25)G Protection of Exposed Reinforcement

When a girder is removed from its casting bed, all prestressing reinforcement strands projecting from the girder shall be cleaned and painted with a minimum dry film thickness of 1 mil of paint conforming to Section 9-08.1(2)B , and all steel reinforcing bars, including M 41-10 Page 6-123 Concrete Structures 6-02welded wire fabric, projecting from the girder shall be protected in accordance with Section 6-02.3(24)B . During handling and shipping, projecting reinforcement shall be protected from bending or breaking. Just before placing concrete around the painted projecting bars or strands, the Contractor shall remove from them all spattered concrete remaining from girder casting, dirt, oil, and other foreign matter.

6-02.3(25)H Finishing

The Contractor shall apply a Class 1 finish, as defined in Section 6-02.3(14) , to:

6-02.3(25)I Fabrication Tolerances

The girders shall be fabricated as shown in the processed shop drawings and shall meet the dimensional tolerances listed below. Construction tolerances of cast-in-place closures for spliced prestressed concrete girders shall conform to the tolerances specified for spliced prestressed concrete girders. Actual acceptance or rejection will depend on how the Engineer believes a defect outside these tolerances will affect the Structure’s strength or appearance:

6-02 Concrete Structures7. Position of an Interior Void, vertically

and horizontally: ± ½ inch

6-02.3(25)J Horizontal Alignment

The Contractor shall check and record the horizontal alignment (sweep) of each girder at the following times:

6-02.3(25)K Vertical Deflection

The Contractor shall check and record the vertical deflection (camber) of each girder at the following times:

6-02 Concrete StructuresIf the girder vertical deflection measured for the erection check (item 3 above) is not

between the lower “D” dimension bound shown in the Plans and the upper “D” dimension bound shown in the Plans plus ¾ inches, the Engineer may require corrective action. The Contractor shall submit a Type 2 Working Drawing for all required corrective actions.

6-02.3(25)L Handling and Storage

The Contractor shall be responsible for safely lifting, shipping, and erecting prestressed concrete girders. During handling and storage, each prestressed concrete girder shall always be kept plumb and upright. It shall be lifted only by the lifting embedments (strand lift loops or high- strength threaded steel bars) at either end. The Contract documents may provide shipping and handling details for girders including lifting embedment locations (L), shipping support locations (L1 and L2), minimum shipping support rotational spring constants (Kθ), minimum shipping support center-to- center wheel spacings (Wcc), vertical deflections and number of temporary top strands. These shipping and handling details have been determined in accordance with Section

6-02.3(25)L2 and are suggested only.

The Contractor shall submit a Type 2E Working Drawing analyzing girder lateral stability and concrete stresses during lifting, storage, shipping and erection in accordance with

6-02.3(25)L1 Lifting and Handling Devices

For strand lift loops in girders with a maximum depth of 3 feet, only ½-inch diameter or 0.6-inch diameter strand conforming to Section 9-07.10 shall be used, and a minimum 2-inch diameter straight pin of a shackle shall be used through the loops. Multiple loops shall be held level in the girder during casting in a manner that allows each loop to carry its share of the load during lifting. The minimum distance from the end of the girder to the centroid of the strand lift loops shall be 3 feet. The loops for all prestressed concrete girders shall project a minimum of 1′-6″ from the top of the girder. Loops shall extend to within 3 inches clear of the bottom of the girder, terminating with a 9-inch long 90-degree hook. Loads on individual loops shall be limited to 12 kips, and the angle between a lifting cable and the top of the girder shall not be less than 60 degrees. For high-strength threaded steel bars, a minimum of two 1⅜-inch diameter bars conforming to Section 9-07.11 shall be used at each end of the girder. The lifting hardware that connects to the bars shall be designed, detailed, and furnished by the Contractor. The minimum distance from the end of the girder to the centroid of the lifting bars shall be 3 feet. Lifting bars shall extend to within 3 inches of the bottom of the girder and shall be anchored in the bottom flange with steel plates and nuts. The minimum size of embedded plates for lifting bars shall be ½ inch thick by 3 inches square. Lifting forces on the lifting bars shall not exceed 58 kips on an individual bar and shall be within 10 degrees of perpendicular to the top of the girder. M 41-10 Page 6-127 Concrete Structures 6-02Lifting loops or embedments for girders with a depth less than 3 feet shall be designed and detailed by the Contractor.

6-02.3(25)L2 Girder Lateral Stability and Stress Analysis

Analysis for girder lateral stability and concrete stresses during lifting, storage, shipping and erection shall be in accordance with the PCI Recommended Practice for Lateral Stability of Precast, Prestressed Concrete Bridge Girders , First Edition, including March 2020 errata, Publication CB-02-16-E and the AASHTO LRFD Bridge Design Specifications edition identified in the Contract documents. The following design criteria shall be met:

6-02 Concrete StructuresVariables are as defined in the AASHTO LRFD Bridge Design Specifications.

The analysis shall address all effects on girder vertical deflection (camber), “A” dimensions at centerline of bearings and deck screed cambers (C). Suggested shipping and handling details provided in the Contract documents have been determined using the following analysis assumptions, unless shown otherwise:

6-02.3(25)L3 Girder Storage

If girders are to be stored, the Contractor shall place them on a stable foundation that will keep them in a vertical position. Stored girders shall be supported at the bearing recesses or, if there are no recesses, approximately 2 to 3 feet from the girder ends. After post- tensioning, spliced prestressed concrete girders shall be supported at points between 2 and 5 feet from the girder ends, unless otherwise shown in the Plans. For long-term storage of girders with initial horizontal curvature, the Contractor may wedge one side of the bottom flange, tilting the girders to control curvature. If the Contractor elects to set girders out of plumb during storage, the Contractor shall have the proposed method analyzed by the Contractor’s engineer to ensure against damaging the girder.

6-02.3(25)L4 Girder Shipping

After the girder has reached its 28-day design strength, the girder and a completed Certification of Compliance, signed by a Precast/Prestressed Concrete Institute Certified Technician or a Professional Engineer, shall be submitted to the Engineer for inspection. If the Engineer finds the certification and the girder to be acceptable, the Engineer will stamp the girder “Approved for Shipment”. M 41-10 Page 6-129 Concrete Structures 6-02No prestressed concrete slab girder shall be shipped for at least 3 days after concrete placement. No prestressed concrete wide flange deck, deck bulb tee or tub girder shall be shipped for at least 7 days after concrete placement, except that they may be shipped 3 days after concrete placement when L/(bd) is less than or equal to 5.0, where L equals the shipping length of the girder, b equals the girder top flange width (for prestressed concrete wide flange deck and deck bulb tee girders) or the bottom flange width (for prestressed concrete tub girders), and d equals the girder depth, all in feet. No other girder shall be shipped for at least 10 days after concrete placement. Girder support locations during shipping shall be no closer than the girder depth to the ends of the girder at the girder centerline. If the Contractor elects to assemble spliced prestressed concrete girders into shipping configurations not shown in the Contract documents, the Contractor shall submit a Type 2E Working Drawing analyzing girder lateral stability and concrete stresses in accordance with Section 6-02.3(25)L2 before shipping.

6-02.3(25)L5 Girder Erection

Before erecting prestressed concrete girders, the Contractor shall submit an erection plan as a Type 2E Working Drawing. The erection plan shall provide complete details of the erection process including at a minimum:

6-02 Concrete StructuresInstead of the oak block wedges shown in the Plans, the Contractor may use Douglas fir

blocks if the grain is vertical. The height of oak block wedges at the girder centerline shall not exceed the width. The Contractor shall fill all block-out holes with a mortar or grout acceptable to the Engineer. Stop plates and dowel bars for prestressed concrete girders shall be set with either epoxy grout conforming to Section 9-26.3 or type IV epoxy bonding agent conforming to Section 9-26.1 .

6-02.3(25)M Girder to Girder Connections

When differential camber between adjacent girders in a span exceeds the tolerance in Section 6-02.3(25)I , the Contractor shall submit a method of equalizing deflections as a Type 1 Working Drawing. All temporary strands in the top flange shall be cut in accordance with Section 6-02.3(25)L5 prior to equalizing girder deflections. Prestressed concrete girders shall be constructed in the following sequence:

6-02.3(26) Post-Tensioned Concrete

Multistrand post-tensioned structures and grouted post-tensioned structures shall conform to the requirements of PTI/ASBI M50.3-19 Specification for Multistrand and Grouted Post-Tensioning . Grouting for post-tensioning systems shall conform to the requirements of PTI M55.1-19 Specification for Grouting of Post-Tensioned Structures . Permanent unbonded single-strand post-tensioning shall conform to the requirements of PTI M10.2-17 Specification for Unbonded Single Strand Tendons . These specifications shall be collectively referred to as the “PTI requirements.” Within the PTI requirements, the term “Construction Engineer” shall be taken as the Engineer.

6-02.3(26)A Post-Tensioning Materials

PTI requirements for materials and components shall not supersede the requirements of

Division 9

Prestressing material shall conform to Section 9-07.10 or Section 9-07.11 . Special prestressing materials shall not be used unless specified in the Contract documents. Post-tensioning systems for multistrand and grouted post-tensioning for permanent structures shall conform to the PTI requirements for Protection Level 2 (PL-2) unless noted otherwise. Grout for post-tensioning tendons shall be a Grout Type 1 in accordance with Section