Effective with the December 2018 Letting 212 2019 Standard Spec ifications Section 502 Concrete Bridges
502.1 Description
1.This section describes constru cting concrete bridges and concr ete parts of other bridges.
502.2 Materials
502.2.1 General
1.Furnish grade A-FA, A-S, A-T, A -IS, A-IP, or A-IT, air-entrain ed concrete conforming to 501 as modified for class I structure concrete in 715. Provide QMP for class I structure concrete as specified in 715.
2.For other materials, c onform to the following: Steel reinforcement ......................................................................................................................................... 505 Structural steel and miscellaneous metals ...................................................................................................... 506 Waterproofing ................................................. ................................................................................................ 516
3.Except for form ties, use hot-dip ped galvanized or epoxy-coate d steel, stainless steel, or non-metallic materials for hardware incorpor ated into the structure. Repair cuts and other damage to galvanized or epoxy coatings according to ASTM A780. Do not use galvanized hardwa re where it is in contact with weathering steel.
502.2.2 Concrete Composition
1.Furnish concrete for bridges conforming to 501. If the contract specifies, or the engineer allows, use high early strength concrete.
2.Do not use high early strength co ncrete in cast in place bridg e superstructures.
3.Do not use high early strength concrete in bridge substructure s or in other structures unless the contract requires it, or if the engineer allows t he contractor, in writing, to use high early strength concrete to expedite the work.
4.Provide the concrete grade specified in 501.3.1.3.3 .
5.Use the coarse aggregate sizes specified in 501.2.5.4.5 and 501.3.2.2 .
502.2.3 Falsework
1.The engineer will not require the contractor to use new or unused materials in falsework.
2.Use timber and piling in falsew ork of adequate strength and sh ape, suitable for the purpose intended. Use material that is in good condition, sound, and free from de fects that might impair its strength. Use reasonably straight piling capable of withstanding pile driving .
3.Use straight steel members, o f adequate strength and shape sui table for the purpose intended.
502.2.4 Forms
1.The contractor may use wood or metal, or, with the engineer’s approval, composite construction. The engineer will not require the use of new, unused material. Use material in good condition, of adequate strength, and of a shape suitable for the purpose intended.
502.2.5 Waterstops
1.If not specified in the contract, the contractor may furnish a nd use either polyvinyl chloride (PVC) or rubberized membrane waterstops. Use polyvinyl chloride waterstops that are a dense, homogeneous material, free from holes and ot her imperfections, extruded fro m an elastomeric plastic compound. If using PVC waterstops, conform to the Corps of Engineers' Specif ication CRD-C 572.
2.Select the rubberized membrane, primer, and mastic from the department's list of engineer-approved waterstop products. Use membrane with a minimum thickness of 60 mils.
502.2.6 Concrete Curing Compound
1.Use liquid curing compound conforming to ASTM C309 , type 1-D, clear or tran slucent with fugitive dye, except as modified in 501.2.9 for testing.
502.2.7 Preformed Joint Filler
Revise 502.2.7(1) to include foam expansion joint materials. This change was implemented in ASP 6 effective with the December 2017 letting.
1.Use preformed joint filler conf orming to AASHTO M153, AASHTO M 213, or ASTM D8139 .
502.2.8 Preformed Elastomer ic Compression Joint Sealer
1.Use preformed elastomeric compression joint sealer conforming to AASHTO M297.
2.If installing the preformed join t sealer, use a lubricant-adhe sive that is a one-part moisture curing polyurethane and hydrocarbon solven t mixture with the following physical properties: Effective with the December 2018 Letting 213 2019 Standard Spec ifications Average weigh t per gallon ..................................... ............................................................... .... 7.2 to 8.8 pounds Solids conten t percent ........................................ ............................................................... ... 72 to 74% by weight Adhesive to remai n fluid from ................................. ........................................................................... 5 F to 120 F Film strength ( ASTM D412 ) ............................................................. ....................................................... 120 0 psi Elongation .................................................... ............................................................... ................................. 350%
3.Ensure the viscosity of the lubr icant-adhesive performs suitab ly with the application equipment. The engineer will reject any lubricant-adhesive not used within 9 m onths of manufacture.
4.Ensure the lubricant-adhesive consistency works well at the te mperatures the seals are installed, is compatible with the seals and t he concrete, and is relatively u naffected by the normal moisture in the concrete.
5.Deliver the lubricant-adhesive in containers plainly marked wi th the manufacturer's name or trademark, lot number, and manufacture date.
6.Use a joint sealer compatible w ith concrete, or steel and resi stant to abrasion, oxidation, oils, gasoline, salt, and other materials spill ed on or applied to the surface.
7.Shape the sealer so that in its compressed condition the top c enter of the exposed surface is depressed below the ed ges of the installed sealer. At the joints maximum opening, the minimum unit pressure on the sides of the joint sealer shall be 3 psi.
8.Mark the top surface of the s eal at one-foot intervals clearly , in a manner durable enough to make length determinations of the seal after installing in the pavem ent joints.
9.Mark shipping containers for se als clearly, with the manufactu rer’s name, the size of the seal, the lot number, and the manufacture date.
502.2.9 Non-Bituminous Joint Sealer
1.Furnish gray sealant complying with ASTM C920 for non-sagging grade NS, class 25, traffic area use T, and either single-componen t type S, or multi-component type M.
502.2.10 Hot-Poured Elastic Joint Sealer
1.Furnish material conforming to ASTM D6690 .
502.2.11 Crack and Surface Sealers
1.Furnish crack and surface s ealers from the department's APL as follows: - Crack sealer: Low Viscosity Crack Sealers for Bridge Decks li st. - Protective surface treatment: C oncrete Protective Surface Tre atment list. - Pigmented surface sealer: Cur e and Seal Compound for Non-traf ficked Surfaces for Structural Masonry list.
502.2.12 Adhesive Anchors
1.Unless the plans show stainless steel, furnish either stainles s steel or galvanized anchors, bolts, studs, nuts, and washers. Ensure that galvanized materials are either hot dipped according to ASTM A153 supplemented by ASTM F2329 or mechanically zinc coated according to ASTM B695. If the plans show using reinforcing bars, use grade 60 bars conforming to AASHTO M31 and to 505.2.
2.Furnish adhesive from the department's APL .
3.Do not substitute adhesive anchor s for anchors the plans show unless the plans allow adhesive anchors. Do not use adhesive anchors in overhead applications w ith sustained tensile loads.
502.2.13 Clear Protective Coating
1.Furnish clear protective coating composed of the following: MATERIAL MINIMUM PERCENT BY WEIGHT Vinyl resin[1] ............................................................................................................................. ...................... 25.0 Methyl ethyl k etone solv ent ................................... ............................................................... ......................... 37.0 Toluene so lvent ............................................... ............................................................... ............................... 37.0 [1] Use resin of an engineer-approved vinyl chloride-acetate copol ymer containing 86 percent vinyl chloride and 14 percent vinyl acetate. Ensure a viscosity of 250-500 centipo ises for a 22 percent by weight solution or resin in a solvent, consisting of equ al parts of methyl iso-butyl ket one and toluene at 77 F. COATING PROPERTY Weight per gal lon at 77 F ..................................... ............................................................... . 7.6 pounds minimum Viscosity a t 77 F ............................................. ............................................................... ........... 60-70 Krebs units Color ......................................................... ............................................................... .............. Clear and colorless Drying time ................................................... ............................................................... ........... 1/2 hour maximum Effective with the December 2018 Letting 214 2019 Standard Spec ifications 502.3 Construction
502.3.1 General
1.Use construction methods conforming to the specifications for the several parts of the structure. Do not slip-form parapets unless the department explicitly allows by special provision. 502.3.2 Falsework
502.3.2 1 Detailed Plans
1.At the engineer’s reque st, the contractor s hall submit one cop y of signed and sealed detailed plans and computations for falsework, as specified in 105.2 , and place on file. If t he engineer re quests, submit 2 additional copies of p lans for review. Revise the plan s as the engineer directs. Understand that whether or not the engineer requests submission of these plans or concurs in the use of the submitted or corrected plans, t he contractor is responsible for obtaining satisfactory results.
502.3.2 2 Design
1.Design falsework to support a weight of 160 pounds per cubic f oot for concrete plus a live load allowance of not less than 10 pou nds per square foot of horizon tal projection of forms; and must also provide the necessary rigidity and support for the loads withou t appreciable settlement or deformation. Consider the potential effects of high wind and high water in t he design.
502.3.2 3 Erection
1.Build falsework on foundations adequate to suppo rt the load wi thout appreciable settlement. Drive an ample quantity of falsework p iling to support the falsework unl ess there is firm foundation material for the support of mud sills that i s not subject to undermining or softening. Construct mud sills of a size and thickness to support the load at the soil’s safe bearing va lue. Generally, found mud sills only on rock, firm sand, gravel, or very firm, silty, sands or clays in their natural beds. Place mud sills founded on well-compacted slopes of berm fills or natural slopes on ben ches, with the edge o f the sill not closer than one foot from the intersec tion of the bench and the surfac e of the slope, except if the engineer allows placing sills on slope paving. The safe design bearing v alue for foundation material, other than rock, under mud sills shall not e xceed 2 tons per square foot. Unless supporting the excavation for footings adequately wi th sheeting, place the edge of the falsew ork sill no closer than 4 feet from the excavation edge.
2.If supporting falsework by mud sills placed on paved, well-com pacted slopes of berm fills, then the contractor shall not strut the fa lsework to columns, unless fou nding the column on rock or supporting by piling.
3.Set falsework at the proper elev ation to produce, in conjuncti on with engineer-approved wedges, shims, or jacks, the specified per manent camber plus a construc tion camber covering allowance for settlement. Construct slabs and gi rder spans to provide a perma nent camber as the plans show.
4.If extending existing concrete b ridges, then extend the falsew ork and forms for the new construction one foot under the edge of the exis ting structure and make the existing structure bear on the falsework by driving wedges between the falsework and the forms.
5.If the plans show, brace and tie the exterior girders supporti ng bridge decks to the interior girders as necessary to preclude rotation o f the exterior girders if suppo rting the deck overhang by knee braces bearing against the ex terior girders.
6.If the plans do not show the abov e requirement, t he contractor shall determine the need for any bracing or stabilizat ion necessary to prev ent girder rotation a nd overhang settlement.
7.The contractor’s responsibility i ncludes obtaining satisfactory results whether or not the plans show a requirement for bracing or stab ilizing the exterior girders.
8.If building falsework over a s tream or lake subject to boating use, construct it to provide ample horizontal and vertical clearanc e for rowboats and small powerb oats to pass. If building falsework over a highway or street used by traffi c provide a minimum clearance , unless the plans show otherwise or special provisions specify ot herwise, of 22 feet horizontal and 13 1/2 feet vertical. Ensure that no part of the falsework protrudes into the clear areas reserved for water or highway traf fic. For signing, conform to plan details or contract provision requirements.
502.3.3 Forms
502.3.3 1 Detailed Plans
1.The engineer reviews the details for formwork, bracing, tying, etc., and will not give permission to place concrete until all this w ork is complete. If the engineer directs, submit detailed plans and computations for forms to the engi neer for examination. Revise the plans as the engineer directs. Effective with the December 2018 Letting 215 2019 Standard Spec ifications Understand that whether or no t the engineer reque sts submission of these plans or concurs in the use of the submitted or corrected pl ans, the contractor is responsi ble for obtaining satisfactory results.
502.3.3 2 Design
1.Design forms to sustain the pres sures resulting from considering concrete without initial set as a liquid weighing 160 pounds per cubic foo t plus a live load allowance of not less than 10 pounds per square foot of horizontal projection of forms. Use substantial and uny ielding forms designed so that the finished concrete conforms to t he proper dimensions and contour s. Design forms to account for vibration forces.
502.3.3 3 Erection
1.Build forms mortar-tight and su fficiently rigid to prevent dis tortion from concret e pressure and other loads that occur due to constru ction operations. Construct and maintain forms to p revent warping and joint openings due to lumber shrinkage, and so they remain true to the lines designated until the concrete hardens sufficiently. F orms shall remain in place for the periods specified below in 502.3.4.
2.If forms appear unsatisfactory in any way, before or during co ncrete placement, the engineer will order the work stopped until correct ion of the defects. If the engine er orders, the contractor shall remove and replace the concrete within the defective area at no expense to the department.
502.3.3 4 Timber Forms
1.Use forms for exposed surfaces made of dressed lumber, of unif orm thickness and make mortar-tight.
2.Fillet the forms with triangular molding chamfer strips at exp osed, sharp corners and at the edges of the concrete. Unless specified otherwise, use triangular moldin g that measures 3/4 inch on the sides.
3.Construct forms for railing, copings, and ornamental work to s tandards equivalent to first-class millwork. Make moldings, panel work, and bevel strips, straight and true, with neatly mitered joints, and design so that the finished work is true, sharp, and clean cut. Exercise special care to secure smooth and tight fitting forms, hold the forms rigidly to line and grade, and remove without injuring the concrete.
4.In forming copings, offsets, and recesses, give the forms suff icient taper to allow removal without damaging the concrete. The maxim um draft shall equal one inch per foot.
5.Use bolts or rods to hold forms in place. Construct metal appl iances used inside forms to hold them to correct alignment and location so that, after removing the form s, removal of the metal to a depth of at least one inch from the surface of the concrete does not injure the surface. Hold bolts or rods in place by attaching devices to the wales that develop the strength of the rod. Fill cavities left by removing bolts and rods with cement mortar conforming to 502.3.7.1 and leave a sound, smooth, and even surface uniform in color. If exposing the completed concrete, u se tie rods of a diame ter, or fitted with cones, or other means to provide cavities large enough to allow filling and finishing with cement mortar.
6.The contractor shall not use spr eaders for metal pipe, precast concrete, or rolled sections unless it removes them while placing the concrete.
7.Secure forms for exposed surface s to the studs or uprights with true horizontal joints.
8.If reusing forms or form lumber m aintain them in clean and goo d condition as to accuracy, shape, strength, rigidity, tightness, and smoothness of surface. Do no t reuse any split, w arped, bulged, or marred lumber, or use lumber with defects that may produce infe rior work.
9.If possible, daylight columnar fo rms at vertical intervals and with sufficient openings to allow free access to forms for inspecting and working the concrete.
502.3.3 5 Metal Forms
1.Apply the above specifications for forms, if they are applicab le, to metal forms carrying an equivalent loading. Use metal forms thick enough so they remain true to sh ape. Countersink bolt and rivet heads in the form face. Use clamps, pin s, or other connection devices designed to hold the forms rigidly together and to allow removal without injuring the concrete. Th e contractor shall not use metal forms that do not present a smooth su rface or line up properly. Exerc ise special care to keep metal forms free from rust, grease, or other foreign matter that tends to d iscolor concrete.
502.3.3 6 Clean Outs
1.For narrow walls and other locations where no reasonable access to the bottom of the forms exists, provide adequate clean-out opening s. Ensure forms are clean and entirely free from chips, dirt, sawdust, nails, wire, and other extraneous matter during concre te placement. Effective with the December 2018 Letting 216 2019 Standard Spec ifications 502.3.3.7 Oiling and Wetting
1.Oil the inside of forms used for exposed concrete surfaces wit h a light, clear, paraffin base oil, or treat with other engineer-approved bond -inhibiting materials that wil l not discolor or injuriously affect the concrete surface. Perform oiling before placing the reinforceme nt. Thoroughly wet forms with water immediately before placing concrete.
502.3.3 8 Lined Forms
1.Use lined forms for the exposed surfaces of endwalls, substruc ture units, retaining walls, rigid frames, underside surfaces of superstruct ures, except slabs between bea ms or girders, the outside surfaces of superstructures, and all railing and parapet surfaces.
2.Ensure lined form surfaces completely contact the concrete fac ed with metal, plywood, composition, or other engineer-approved material to the engineer’s satisfaction . Submit samples, specifications, and other pertinent information on these forms to the engineer if r equested and secure the engineer’s permission to use the contemplated form lining.
3.Form lining material shall not bulge, warp or blister, or stai n the concrete. Keep the number of pieces of material used line forms to a minimum. Make splices in form lining material neatly and break joints with the form material.
4.The contractor may use forms constructed of metal, plywood, or other engineer-approved material that satisfactorily produces the desired surface finish for the conc rete instead of lined forms.
502.3.3 9 Cylindrical Column Forms
1.If forming cylindrical columns w ith fiber pulpboard tubes, use truly cylindrical tubes of uniform diameter and with adequate strength to supp ort the concrete. Ensure that the surfaces of the tube are waterproof with a treated interior surface that prevents adhesi on of the tube to the concrete and after finishing, does not leave protruding seams or fins. The tube sh all provide a smooth and true column surface, free from discoloration.
502.3.4 Removing Forms and Falsework
502.3.4 1 Removing Forms
1.If removing forms under slabs , beams, girders, brackets, and s upports, conform to the removal requirements for falsework specified below in 502.3.4.2 . The contractor may remove all other forms 12 hours after casting concrete if t he concrete is sufficiently se t to be self-supporting.
2.If forms are an integral part o f the falsework, keep them in p lace until falsework removal. During hot weather, use water, as the engi neer directs, to cool the concrete within the forms.
3.Remove forms in a manner causi ng no injury to the concrete.
502.3.4 2 Removing Falsework
1.Do not remove falsework and form supports without the engineer 's approval. Remove supports in a way that allows the concrete to uniformly and gradually take th e stresses due to its own mass.
2.In determining the removal time of falsework, consider the loc ation and character o f the structure, the weather, the materials used in t he mix, and other conditions in fluencing the concrete setting.
3.The engineer may determine when to remove falsework or form su pports by using test cylinders or by using the minimum requirements specified below: 1. If not controlling field operations by cylinder tests, keep falsework supporting concrete in bridges, including slabs, beams, girders, a rches, or concrete slabs on steel or co ncrete girders in place according to the minimum requirements for equivalent curing days specified in 502.3.10.1. Except do not remove falsework from cast in place bridge slab decks or box girder spans until at least 7 days elapse, fo r deflection control, exclude days that the concrete s urface was subjected to tempera tures below 40 F. 2. If controlling field operations by cylinder tests, remove f alsework or form supports, with the engineer's approval, when the tests of cylinders show a concrete compressi ve strength of not less than 2000 psi for spans 12 feet or less; and not l ess than 2500 psi for spans ove r 12 feet. Except, do not remove falsework from cast-in-place bridge slab decks or box girder spans until at least 7 days elapse, fo r deflection control; exclude days that the concrete s urface was subjected to tempera tures below 40 F.
4.Double the length of the horizont al projection of cantilevered portions of piers, abutments, and similar sections for determining span length for falsework removal.
5.Test at least 2 cylinders to det ermine the attained strength o f concrete for falsew ork removal. Use the average test results for the 2 cylinders to determine complianc e, except that both cylinders must be no less than 10 percent below the requ ired strength. Cure the cylinders under conditions that at best equal the most unfavorable conditi ons for concrete sampled that the cylinders represent. Effective with the December 2018 Letting 217 2019 Standard Spec ifications (6) Remove falsework piles down to at least 24 inches below stream bed or finished ground line. Remove temporary mud sills and footings.
7.For multiple concrete spans of continuous design, do not remov e the falsework from any one span until the concrete in an entire unit of continuous span cures f or the required time. If providing a longitudinal joint in the roadwa y of any one span, do not remov e the falsework from any portion of the span until the entire span cures for the required time.
502.3.5 Handling and Placing Concrete
502.3.5 1 General
1.Notify the engineer before placin g concrete to allow inspectio n of the forms, reinforcement, and placement preparations.
2.Before placing any concrete in a given pour, have sufficient l abor, material, and equipment at the work site to complete the pour. Use equipment that is adequate for t he work and in first-class working order.
3.Complete the forming and placing reinforcement before placing the concrete in any unit. Place and rigidly support in the correct position all bar steel reinforce ment extending into a subsequent pour before placing the first concrete in a given pour, unless the plans show otherwise. Complete adjacent pile driving and other operations detrimental to freshly placed concrete before placing concrete.
4.Before placing concrete, remov e sawdust, chips, nails, wire, o ther construction debris, and extraneous matter from the forms interior. C lean the contact surfaces of s tructural steel members embedded in the placed concrete to ensure they are free from oil, grease, loose rust scale, or other materials that would affect the bond between the concrete and the steel.
5.The contractor shall not support c onstruction equipment on rei nforcement steel or bar chairs.
6.Place the concrete in a way tha t avoids segregating the aggreg ate or displacing the reinforcement. If the engineer finds any defective concrete section, remove and r eplace it, as the engineer directs, at no expense to the department.
7.Arrange and use chut es, troughs, belts, and pipes as aids in p lacing concrete so no separation of the concrete ingredients occur. Provide enough chutes, troughs, or pipes to carry the concrete up at a uniform level without shifting them. Keep chutes, troughs, belt s, and pipes clean and free from coatings of hardened concrete. Discharge water used for flushin g away from the concrete in place.
8.If placing concrete in structur es, the distance from the disch arge ends to the point of deposit for chutes, troughs, pipes, belts, and buckets shall not exceed 4 f eet.
9.If using conveyor belt systems , equip the belts with suitable hoods or chutes to control the discharge.
10.If conveying or placing concrete by pumping, use suitable equi pment with adequate capacity for the work. Arrange the equipment so tha t any resulting vibrations do not damage freshly placed concrete. Operate the pump in a way that p roduces a continuous stream of concrete without air pockets. After pumping is complete, if using the concrete remaining in the pip eline, eject it so there is no concrete contamination or ingredients sep aration. After this operation, thoroughly clean the equipment.
11.If placing concrete by pumping, take measures to minimize entr ained air loss. The point of discharge from the flexible hose at the end of the boom shall be higher than the lowest point of the flexible hose. If using an extended boom, the contractor may lay part of the f lexible hose on the deck. If completely suspending the flexible hose fr om the boom, tie the discharge e nd of the flexible hose back toward the end of the rigid boom to form a partial loop. The engineer may approve alternate methods if the contractor can demonstrate that the air loss in the concrete created by the pumping process does not exceed 1.0 percent in any boom orientation.
12.The contractor shall not use a luminum pipes, chutes, troughs, spouts, or tremies for pumping, conveying, or placing concrete.
13.If placing operations involve placing concrete through the com pleted forms, as for , piers, columns, and retaining walls over 5 feet in height, with the exception of ca st in place concrete piles and walls less than 10 inches thick, deposit concrete through sheet metal or o ther engineer-approved pipes. Assemble these pipes in section s to facilitate adjusting outlets to proper heights during pouring operations. The distance from t he bottom of these pipes to the point of deposit shall not exceed 4 feet at any time.
14.If using troughs or chutes, extend them down inside the forms, or through holes left in the forms, to within 2 feet of the point of deposit unless they end in vertic al downspouts that extend to within 4 feet of the point of deposit. Equip steep chutes with baffle boards or assemble them in short lengths that reverse the direction of movem ent. The contractor shall not use long chutes for conveying concrete from the mixing plant to the forms. Effective with the December 2018 Letting 218 2019 Standard Spec ifications (15) Place concrete in continuous hor izontal layers approximately 12 inches thick, except that the engineer may allow increasing this thickn ess to 24 inches. Place each la yer in a continuous pour and consolidate before the concrete i n the preceding layer takes in itial set.
16.Make construction joints only at locations the plans show, unless the engineer dir ects otherwise. In case of an emergency, place construction joints at the engineer ’s direction. Use shear keys or inclined reinforcement at necessary points to transmit shear, or bond th e 2 sections together.
17.Regulate placing the concrete so that the pressure of the conc rete does not exceed that of the form design.
18.Take special care to fill each part of the forms by depositing concrete directly as near the final position as possible, to work the coarse aggregate back from the face, a nd to force the concrete under and around the reinforcement bars wi thout displacing them. Also, tr y to prevent spattering the forms or reinforcement bars so that the sp attered concrete does not dry or harden before incorporating into the mix. Clean foreign material from reinforcement bars before the succeeding pour.
19.Remove all removable form spread ers before placing concrete at the spreader elevation.
20.Take care to avoid accumulating laitance or foreign matter ins ide forms, recesses, or corners. Provide openings in forms for removing any accumulations, as the engine er directs.
21.After the concrete takes initia l set, avoid jarring the forms or placing any strain on the ends of projecting reinforcement.
22.Use mechanical vibration to consolidate the concrete for super structures. Consolidate other concrete for structures by vibrating unless using other methods the engi neer finds satisfactory. Use vibrators capable of operating at frequencies sufficient to achieve thoro ugh and uniform consolidation, but at not less than 7000 impulses per minute. Make available at least one spare vibrator, in working order and of sufficient frequency, on the wo rk site before pouring concre te.
23.Apply vibration to the freshly deposited concrete by slowly in serting and withdrawing the vibrator. Perform this procedure at enough locations and for as long as n ecessary to uniformly and thoroughly consolidate the entire weight of fresh concrete without causing aggregate segregation, or forming localized areas of mortar.
24.Consolidate each concrete laye r thoroughly before placing the next layer on top. Ensure that the vibrator penetrates through each successive layer and sufficiently into the preceding layer to uniformly blend the 2 concrete layers together.
25.The contractor shall not perform vibration directly to or thro ugh the reinforcement of sections or layers that harden so that they are no longer plastic under vibration. The contractor shall not use the vibrator to transport, or to flow , the concrete within the forms to the extent of causing segregation.
26.Supplement vibration with as mu ch spading as necessary, to ens ure smooth surfaces and dense concrete, along form surfaces and in corners and locations impo ssible to reach with the vibrator.
27.If required to continue mixing, p lacing, or finishing concrete after daylight hours, employ artificial light at the work site to the engineer’s satisfaction.
502.3.5 2 Substructures
1.If possible, place concrete for substructures in unwatered fou ndation pits. The contractor may omit the forms and fill the entire exca vation with concrete, if the mate rial type encountered in excavation for structures allows plac ing concrete for footings wholly or in part without forms, and if the engineer approves.
2.Place concrete in columns in one continuous operation unless t he engineer specifies or the plans show otherwise. Allow the concrete to set at least 12 hours bef ore placing the concrete in the cap, cross girder, or superstructure.
3.If the plans show, ensure the t horough and effective drainage of the filling material behind culverts, retaining walls, and abutments by placing weep holes in conjunc tion with the construction specified in
206.3.12 Discharge the drainage water th rough the abutment, the wall o f the culvert, or through the
retaining wall in a manner and at locations that do not cause d iscoloration of exposed masonry surfaces. Form weep holes and, i f necessary, fit with suitable screens or gratings to protect the intake against clogging. Constructing we ep holes the plans show is inc idental to the work.
4.The contractor shall not place c oncrete on a frozen foundation .
502.3.5 3 Depositing Concrete Underwater
1.Deposit concrete unde rwater only if the engi neer orders, the p lans show, or the contract specifies.
2.Provide concrete as specified in 501, except increase the slump to 5 - 9 inches without exceeding t he maximum mix water allowed for that grade. Effective with the December 2018 Letting 219 2019 Standard Spec ifications (3) For concrete deposited underwate r, place it carefully in a compacted weight in its final position using a tremie. The tremie consists of a tube that has a diameter of no t less than 10 inches and constructed in sections having flanged couplings fitted with gaskets. The trem ie support shall allow free movement of the discharge end over the entire work surface and allow its ra pid lowering if neces sary to choke off or retard the flow. Keep the dischar ge end sealed at all times and the tremie tube full to the bottom of the hopper. If dumping a batch into the hopper, raise the tremie sl ightly, but not out of the concrete at the bottom, until the batch discharges to the bottom of the hopper. Then stop the flow by lowering the tremie. Ensure a continuous unint errupted flow until the work i s complete. The contractor may use a tremie equipped with a suitable mechanical seal or valve at the discharge point instead of the open tube tremie, if the engineer appr oves of the design, method of operation, and control of the device.
4.Exercise special care not to disturb concrete deposited underw ater and to maintain still water at the deposit point. The contractor s hall not place concrete in runni ng water. Ensure watertight formwork.
5.Place the concrete in a way tha t precludes developing a cold joint between successive layers or placement stages. Accomplish this by either placing the concret e layers deep enough to accommodate satisfactory tremie operation, while ensuring that the previously layer does not take initial set by pouring at a rat e sufficient to raise the concrete level between 1 1/2 to 2 feet per hour; or by placing the concrete full depth in one continuous operation and completing the work to grade progressively from one end of the coffe rdam to the other.
6.Design cofferdams to accommodat e appropriate and planned pour rates. The contractor may place underwater concrete by pumping, if the engineer approves.
7.The contractor shall not dewat er the cofferdam until at least 3 days pass from the time placed and not before the concrete hardens and is strong enough to withstand t he hydrostatic pressure.
8.After dewatering, remove laitance or other unsatisfactory material on the top of seals and underlying proposed substructure units by scraping, chipping, or other mea ns.
502.3.5 4 Superstructures
1.Except for parapets or similar pours, the contractor shall not place concrete in bridge decks if housing is required at time of placement, unless the engineer specifically allows or requires in writing. Except for rigid frame bridges, remove the forms for the substructure units that support any proposed superstructure before placing the superstructure.
2.Ensure continuous concrete place ment in superstructures betwee n joints the plans show.
3.Exercise care to minimize honeycombed concrete. The engineer m ay require the removal and replacement of honeycombed concrete at no expense to the depart ment.
4.Do not place concrete parapets, sidewalks, and medians on cast in place structures until the falsework is released for that superstruct ure unit. The contractor may pl ace those portions o f the railings directly attached to substructure units w hile the falsework is in place.
5.The contractor may form and place concrete parapets, sidewalks and medians on steel girder, I-beam, or pre-stressed girder structures after 48 hours following deck placement, provided it uses no heavy equipment on the deck and it properly cures the deck adjacent t o the pours.
6.Place floor drains, conduits, e xpansion joints, and other fittings as the plans show. Place and securely fastened them before placing the concrete.
7.Before placing concrete floors on steel superstructures, release the falsework and swing the span free on its supports.
502.3.6 Joints
502.3.6 1 General
1.Construction joints are those joints that do not provide for m ovement of abutting surfaces. Expansion joints are those joints that pro vide for movement by sliding or by deflection. Contraction joints are those joints that provide for ac commodating movement resulting from contraction, and control cracking.
2.Place joints only at the locations that the plans show. The co ntractor shall not omit any joints the plans show, except upon the engineer’s written authorization. If cons tructing joints not as the plans show, but required due to emergency, use shear keys or inclined reinf orcement at locations necessary to transmit shear, or to bond the 2 sections together.
3.The contractor shall not edge jo ints that have reinforcing ste el carried through.
4.Conform to the plans for constructing construction, expansion, and contraction joints. Unless the plans show otherwise, make joints nor mal to the forms. Provide bulkhe ads for all except horizontal joints. Ensure that joints are true to alignment and uniform in width. Effective with the December 2018 Letting 220 2019 Standard Spec ifications (5) If the plans show, seal expansion joints with a hot-poured ela stic joint sealer, conforming to 502.2.10. Seal contraction joints with a non-bituminous joint sealer conf orming to 502.2.9 .
502.3.6 2 Construction Joints
1.Form keyed construction joint s by inserting and subsequently r emoving a template. Use a method to insert and remove the template that avoids chipping, breaking, or damaging the concrete.
2.If joining fresh concrete to con crete previously set, remove loose material, laitance, dirt, and foreign matter from the previously set c oncrete surface and keep the su rface saturated with water until the new concrete is placed. Immediat ely before placing the new conc rete, draw forms tightly against the previously set concrete.
502.3.6 3 Expansion Joints
502.3.6 3.1 Preformed Joint Filler
1.Use preformed joint filler conforming to 502.2.7 , carefully placed, and accurately fit to the adjacent concrete. Take special care to p revent displacing the joint fil ler during concrete placing and to prevent forming concrete fins under or between the sections of material . Do not assemble a series of small pieces of joint filler to produce a shape that could be cut fro m a single piece. Edge or chamfer exposed concrete edges adjacent to prefo rmed fillers, as the plans show .
502.3.6 3.2 Preformed Elastomeric Compression Joint Sealer
1.Use preformed elastomeric compression joint sealer conforming to 502.2.8 and install in the joint with a lubricant-adhesive.
2.Clean joint faces to ensure they are free of laitance, oils, g reases, dirt, free water, and other foreign matter immediately before inst alling the seal. The engineer will direct the method of cleaning the joints.
3.Install the seals, in the pro perly prepared joint, using tools designed for installin g joint seals. Remove and replace any seal damaged du ring installation with an undama ged seal. Remove and reinstall any seal improperly positioned in the joint at the proper elevation .
4.Before placement, cut the seal s to the lengths of the joints o r as much longer as needed for proper installation. Measure each seal b efore and after installing as a check against stretch. Remove and reinstall any installed seal sho wing more than 5 percent stretc h.
5.Install the seals so they are s ecure and free from any objectionable curling or twisting in the joint groove. Use a lubricant to facilit ate installation and to cover both sides of the seal over the full area in contact with the sides of the joint. The contractor may apply t he lubricant to the joint faces, or the seal, or both. Install the seals in a highly compress ed state and ens ure the top of the seal is below the pavement surface by approximately 1/8 inch but not more than 3/ 8 inch. Install the seal in one piece, without field or factory splicing, for the full length of each transverse joint.
6.Observe the manufacturer-specif ied temperature limitations.
502.3.6 3.3 Expansion Device
1.Use an expansion dev ice conforming to one of the models the sp ecial provisions show.
2.Install the steel extrusions with field splices located to mat ch the stage construction. The department will not allow welding in the steel extrusion’s internal sectio n where the neoprene ex trusion is located. Weld splices conforming to the following: For steel: AWS D 1.5, Bridge Welding Code. For stainless steel: AWS D 1.6, Structural Welding Code - Stain less Steel. Revise 502.3.6.3.3(3) to require an inspector from the c ontractor's current field welding plan described in (DT2337).
3.Visually inspect and certify t he quality of field welds as fol lows: 1 . Designate an inspector listed in the current contractor field w elding plan describ ed in department form DT2337. 2. Have the desig nated inspector comp lete department form DT2320 and submit to the engi neer for inclusion in the permanent project record.
4.Blast clean the steel extrusion’s internal section that comes in contact with the neoprene extrusion so that all surfaces are dry, free from dirt, grease, and contamin ants before installing the neoprene extrusion and cover or fill this internal section before placin g concrete, to preve nt concrete from entering.
502.3.6 4 Waterstops
1.Waterproof construction and expansion joints, if the plans show, by installing rubberized membrane or polyvinyl chloride waterstops. Make the field splices for rubbe rized membrane or polyvinyl chloride Effective with the December 2018 Letting 221 2019 Standard Spec ifications waterstops watertight. Install r ubberized membrane waterstops a s specified for rubberized membrane in 516.3.3 . Install polyvinyl waterstops as the plans show.
2.Install waterstops so they do not transfer forces into the con crete embedded in until the concrete is sufficiently strong to w ithstand that force.
502.3.7 Surface Finish of Concrete
502.3.7 1 General
1.After removing forms, remove me tal devices used to tie forms t ogether in a way that leaves no metal within less than one inch of the concrete sur face and does not injure the concrete surface. The contractor shall not burn off r ods, bolts, or other metal devic es. After removing the ties, roughen the opening and remove concrete containing any oil.
2.Immediately after removing forms, saturate cavities produced, and other holes, depressions, and honeycomb spots with water and carefully point with a cement an d fine aggregate mortar mixed in the same proportions as the concrete being treated and of as dry a consistency as possible to use. For exposed surfaces, add as much whit e cement as necessary to prov ide a mortar the approximate color of the concrete. Use mortar in pointing that is not more than one hour old.
3.Clean open joints in the comple ted work to make them free of m ortar and concrete.
4.If using insulated forms or if a llowed to leave forms in place more than 72 hours, poi nt holes, cavities, depressions, and honeycomb areas and apply a sack rubbed or rub bed surface finish as soon after removing the forms as weather and curing conditions allow.
502.3.7 2 Ordinary Surface Finish
1.Unless specified otherwise, pro vide an ordinary surface finish on formed surfaces.
2.Work the concrete up against form ed surfaces during placement by using engineer-approved concrete vibrators or spading implements. Force coarse aggregate from the surface, and thoroughly work the mortar against the forms to produce as smooth a finish as possi ble, free from wat er pockets, air bubbles, and honeycomb.
3.Immediately after form removal, point tie rod holes, pits, or defects and remove or correct fins and irregularities. If the engineer det ermines the final surface is not satisfactory and that an ordinary surface finish was not provided, apply a rubbed surface finish conforming to 502.3.7.3 to the affected exposed areas. There is no requirement to extend the rubbed surface finish into nondefective areas solely to obtain a uniform texture.
502.3.7 3 Rubbed Surface Finish
1.Apply a rubbed surface finish b y carefully rubbing the ordinar y surface finish with a fine carborundum brick immediately after removing the forms. Begin by moistening the surface with water and then immediately rubbing it with the carborundum brick, using light pressure and a circular motion. Continue rubbing until filling air holes and small depressions and a thi n, uniform coating of mortar is on the surface and until obtaining a smooth surface, free from lumber marks and irregularities.
2.The contractor may employ mach ine methods to produce the rubbe d surface finish if the engineer approves.
3.Keep rubbed surfaces wet and covered for at least 4 days or cu re by applying membrane curing material as specified in 502.3.8 .
4.Before acceptance, remove lat her, powder, and dust on rubbed s urfaces.
502.3.7 4 Float Surface Finish
1.Unless specified otherwise, apply a float surface finish to al l unformed upper surfaces.
2.To provide a float surface fini sh, place excess material in th e forms and remove or strike off the excess with a wooden template, forc ing the coarse aggregate bel ow the mortar surface. After striking off the concrete, work the surfac e thoroughly with a wooden flo at. Before this last finish sets, lightly stripe surfaces finished this way and exposed in the finished w ork with a fine brush to remove the surface cement film and leave a fine-grained, smooth, but sande d texture.
3.The contractor shall not mortar top surfaces that will receive a float surface finish.
502.3.7 5 Sack Rubbed Surface Finish
1.If the plans show, or specifications indicate, provide a sack rubbed finish on concrete surfaces.
2.Before applying the sack-rubbe d finish fill tie rod holes and large cavities and re move or correct fins and irregularities as specified in 502.3.7.1 and 502.3.7.2 .
3.Produce a sack rubbed surface finish by rubbing the concrete s urface with a clean rubber float or wad of burlap and mortar. Use mortar made of one part cement and 2 parts, by volume, sand passing a Effective with the December 2018 Letting 222 2019 Standard Spec ifications No. 16 sieve, mixed with suffici ent water to provide a consiste ncy equal to that of thick cream. Use the same type and brand cement as used in the concrete. If necessar y, blend white cement into the cement to match the surrounding concrete surface.
4.Thoroughly wet the surface of t he concrete and then perform sa ck rubbing while the surface is damp but not wet. Thoroughly rub the mo rtar over the area with a rubber float or wad of burlap, filling pits. While the mortar is still plasti c in the pits, rub the surface with the rubber float or burlap using a dry mix of the above proportions, removi ng excess plastic material and placing enough dry material in the pits to stiffen and solidify the mort ar, then finish the mortar fillings flush with the surface. At the end of the rubbing, no mortar or material s hall remain on the surface othe r than that within the pits.
5.Ensure the completed surface is free of surface voids and blem ishes, and is uniform in appearance and texture, except for the difference in texture between the f illed voids and the remainder of the surface.
502.3.7 6 Substructures
1.Provide an ordinary surface finish for formed faces of substructure units. Except, give exposed formed surfaces of parapets built integrally with substructure units t he same surface finish specified for similar work on superstructures in 502.3.7.7 . Rubbed or special surface finish is not required for any form ed faces of substructure units unle ss the plans or special provisi ons require, or as specified in 502.3.7.2 for applying a rubbed surface finish.
2.Strike off and float bent caps, b ridge seats, tops of parapet walls supporting a s uperimposed load, and tops of piers with a wooden floa t as specified for float surfac e finish. Before this last finish sets, steel trowel the entire area. If finishin g areas to receive bearing p lates, secure a true plane at the correct elevation. 502.3.7.7 Superstructures
1.Apply a sack rubbed surface finish to exposed formed surfaces of parapets, posts, and sidewalks as well as to exposed side surfaces of superstructures, including the outer face of outside pre-stressed girders as specified in 503.3.3.4 , unless the special provis ions specify otherwise.
2.There is no requirement to provi de a rubbed surface finish for any formed surface of superstructures, unless the plans or special provisions require it, except if, t he engineer determines the sack rubbed finish provided is unsatisfact ory, then the contractor shall ap ply a rubbed surface finish conforming to
502.3.7 3 to the affected exposed areas.
3.Strike off and float the tops of s afety curbs, sidewalks, or c opings that serve as sidewalks in the completed structure with a woo den float as specified for float surface finish. Before this last finish sets, steel trowel these areas and then brush them.
502.3.7 8 Floors
1.Prepare the concrete for bridge floors, if and as required in 501.3.2.4.3, with a retarding admixture. Deliver the mixed concrete at a uniform rate to provide a conti nuous placing operation for each pour section. Handle and place the co ncrete by methods and equipment that minimize segregating the ingredients. Deposit it as clos ely as possible to its final pos ition without forming piles and so that it requires a minimum of rehandling.
2.Immediately after depositing the concrete, consolidate, strike off, screed, and finish it to the required grade, section, and surface tolerance. Uniformly consolidate th e concrete by internal vibratory methods as specified in 502.3.5.1 , except that, the contractor may use a vibratory screed for consolidating and finishing in conjunction with internal vibration. Operate the internal vibrators or the vibratory screed, or both, in a way that avoids over-vibration.
3.Unless the contract specifies o therwise, construct concrete br idge floors with self-propelled machine finishers.
4.Use a machine finisher designed for finishing bridge floors. I t shall consist of a rig id supporting frame mounted on wheels that ride on re movable tracks or rails and is equipped with the necessary screeding apparatus to strike o ff and finish the concrete to re quired crown and grade. It shall have one or more power-driven oscillating , rotating or vibratory screeds . The screeds may suspend from the machine either transversely or longitudinally with the bridge c enterline, except as required for skew angles of 20 degrees or greater. Use a finishing machine capable of propelling itsel f both forward and backward to allow repeated passe s of the screed in order to cor rect surface irregularities. Adjust its screed or screeds and operate in manner that finishes the concr ete to required grade and crown and requires a minimum of cutting or filling in any subsequent floa t-finishing operations.
5.The contractor shall set the ra ils or tracks, that the machine finisher rides on, to t he required elevation; and ensure they adjus t to allow for settlement under load. If t he rail supports are located in the Effective with the December 2018 Letting 223 2019 Standard Spec ifications concrete, ensure their removal without disturbing the concrete, or partially remove so that no piece remains less than 2 inches below the finished concrete surface. Remove these supports, fill the resulting holes with concrete, and finish flush with the deck c oncrete before it hardens.
6.Ensure the rails or tracks ex tend beyond each end of the floor or deck sufficien tly to support the finishing machine a t the correct grade and entirely free of the floor or deck area.
7.Finish floor areas inaccessibl e to machine operation by hand m ethods.
8.On bridge decks supported on pr estressed concrete or steel girders and having skew angles of 20 degrees or greater, operate the finishing machine so that its l ongitudinal axis is within 20 degrees of the centerline of bearing of the substructure units. Make trans verse screeds parallel to the longitudinal axis of the machine.
9.If using hand-operated strike-off screeds, design , construct, and operate them to provide the required crown and grade in the finished floor. The contractor may use v ibratory or nonvibratory type screeds that operate on forms or temporary guides set and maintained at the required elevation. Use sectioned, temporary guides that remain rigid an d unyielding un der screed operation and, if located within the pour limits, can be removed as the work progresses. If using vibratory screeds to supplement required internal vibration, operate them so they do not over vibrate the concrete.
10.Hand finish gutter lines and areas around floor drains not rea ched by the templates and finishing equipment to the grade an d section needed to i nsure proper drai nage.
11.Strike off and remove the la itance from floor areas that will receive concrete for sidewalks or similar items.
12.Following screeding, unless obtaining a satisfactory surface w ith a self-propelled finishing machine, float the surface as needed to produce a uniform surface.
13.While the concrete is still plas tic and following screeding op erations, and float finishing if performed, work laitance, surplus water, and inert material off the floor and make it smooth. Test for smoothness by dragging the entire floor surf ace with a 10-foot straightedge as specified in 415.3.6.1 for straightedging concret e pavement. Use bridges to facilitate str aightedge operations on pour sections wider than 2 lanes. Revise 502.3.7.8(14) to require transverse tining for bridge decks unless specified otherwise. This change was implemented in ASP 6 effective with the December 2017 letting.
14.Unless specified otherwise, transversely tine finish the floors of struc tures with approach pavements designed for speeds of 40 mph or greater as specified in 415.3.8.3 , except make the tining 1/8 inch in depth and do not perform tining within 12 inches of gutters. Th e contractor may apply a broom finish, described below, instead of the ar tificial turf drag finish req uired before tining. The contractor may perform tining manually, if it obtains a finish satisfactory to the engineer. Perform tining within 20 degrees of the centerline of bearing of the su bstructure units on bridge decks havi ng skew angles of 20 degrees or greater.
15.Unless specified otherwise, provide a turf drag finish on floo rs of structures wit h approach pavements designed for speeds of less than 40 mph as specified in 415.3.8.2 or provide a broom finish. If providing a broom finish, draw the broom transversely across the full width of the pavement with adjacent strokes slightly overlapping. Perform brooming to produce uniform corrugations and approximately 1/8 inch in depth. C omplete brooming before the c oncrete hardens and this operation tears or roughens the surface. Bro oming shall provide a surface free from rough or porous areas, irregularities, and depressions that result from improper broom handling. Furnish br ooms of a sufficient quality, size, and construction, and operate them to produce a surface finish the engineer approves. Provided the contractor obtains satisfactory re sults, the engin eer will allow manual brooming instead of mechanical brooming.
16.The finished bridge floor shall conform to the surface test sp ecified in 415.3.10 . The engineer will not direct corrective grinding without authorization from the depar tment’s bureau of structures.
17.Make available suitable platfo rms to use, as required, over steel reinforcement projecting from previously placed concrete, duri ng the period necessary for the concrete to achieve sufficient strength to preclude damage from contract or's operations on the unprotec ted reinforcement.
18.Make available adequate bridges , if and as the engineer requir es, for inspecting and testing the placed concrete, and furnish bridges, i f necessary, to perform work op erations that follow the screeding operations. Effective with the December 2018 Letting 224 2019 Standard Spec ifications 502.3.8 Curing
502.3.8 1 General
1.Maintain adequate moisture throughout the concrete mass to sup port hydration until the concrete develops sufficient strength to open it to service. Cure concre te by one or a combination of the following methods: 1. Impervious coating. 2. Impervious sheeting. 3. Continuous wet cure. 4. Alternate method the engineer approves.
2.If the contractor fails to cure concrete as specified here in 502.3.8, the engineer may suspend concrete placement operations.
502.3.8 1.1 Impervi ous Coating Method
1.After finishing operations, and as soon as the free water disa ppears, spray the concrete surface with a uniform coating of curing compound conforming to 502.2.6. Seal moisture in the concrete by applying a continuous water-impermeable film on exposed concrete surface s.
2.Provide sufficient agitation of pigment within the curing comp ound during spraying to ensure uniform consistency and dispersion as applied.
3.Apply the curing com pound with spraying equipment that produce s a continuous, uniform film that does not run or sag.
4.Apply the curing compound unifo rmly at a minimum rate of one g allon per 150 squar e feet. Apply the membrane curing material in 2 applications at the rate of not l ess than one gallon per 300 square feet.
5.If damage to the curing compound coating occurs before the con crete conforms to the opening criteria specified in 502.3.10 , recoat the affected area immedi ately. If removing forms befor e the concrete conforms to the opening criteria specified in 502.3.10 , coat newly exposed surfaces within 30 minutes after form removal. 502.3.8.1.2 Impervious Sheeting Method
1.As soon as the concrete receives a finish and hardens sufficie ntly to prevent excess ive marring, cover exposed concrete surfaces with one or a combination of the foll owing impervious sheeting materials: 1. Polyethylene sheeting confor ming to the curing materials sp ecified in 501.2.9. 2. Polyethylene-coated burlap conforming to the curing materia ls specified in 501.2.9 . Pre-wet the polyethylene-coated burlap and pl ace with the uncoated side aga inst the concrete. 3. Insulated curing blankets with an impervious coating, with the engineer's approval. 4. Alternate impervious sheeti ng materials, with the engineer' s approval.
2.Provide sheeting material sufficient to cover exposed surfaces and edges, with enough excess to hold the material securely in place b y weighting or an alternate anc horing method. Provide a minimum of 12 inches overlap between adjacent pieces of sheeting. Place th e sheeting material so that it is in direct contact with exposed concrete surfaces.
3.Maintain the sheeting material in place until the concrete con forms to the opening criteria specified in
502.3.10 If temporary removal is required, to remove forms or perform other necessary work, re-cover
exposed concrete as quickly as practicable, or as the engineer directs.
4.If the engineer approves , the contractor may reuse sheeting ma terials in serviceable condition.
502.3.8 1.3 Continuous Wet Cure Method
1.As soon as the concrete receives a finish and hardens sufficie ntly to prevent excess ive marring, spray or fog the exposed surfaces of t he concrete to keep it moist un til the concrete conforms to the opening criteria specified in 502.3.10 . Apply a layer of thoroughly wetted burlap to protect the surf ace from the mechanical impact of the spray.
2.If the concrete surface shows e vidence of erosion by the curin g water, the engineer will immediately suspend the spraying or fogging. R emedy the conditions causing erosion or switch to another cure method that does not involve continuous wet cure.
3.If ambient temperatures are pr edicted to fall below 32 F withi n the next 24 hours, suspend continuous wet curing and switch to another curing method. Effective with the December 2018 Letting 225 2019 Standard Spec ifications 502.3.8.1.4 Alternate Curing Methods
1.If the contractor requests, the engineer ma y approve using alt ernate materials or curing methods. Supply technical specifications , test results, or performance r ecords to support its proposed alternative method, if the engineer requests.
502.3.8 2 Curing Requirements
502.3.8 2.1 General
1.Do not use reinforcing steel to s upport or attach covering mat erials.
2.If curing formed concrete by t he impervious coating method, ap ply the first application immediately after form removal and surface finish application. If the surfa ce is dry, wet the concrete thoroughly with water and apply the curing compo und just as the surface film of water disappears. Apply the second application as soon as the first application sets.
3.Do not apply impervious coati ng curing material to constructio n joints, or to surfaces being bonded to other concrete, or to surfaces being waterproofed, or to which applying sealants. Ensure that steel reinforcement, anchors, watersto ps, and similar devices are fre e of compound before placing concrete.
4.Do not use the impervious coating method on concrete before applying the required surface finish. Use other allowed curing procedur es before applying the surface finish.
5.The contractor may delay applying the required surface finish, if the engineer approves, until after completing curing with wetted burlap or polyethylene-coated bur lap, in order to allow uniform and continuous finish application. P rovide at least 4 hours of an e ngineer-approved moisture cure to prevent the finish from sanding-out.
6.If the structure or any portion of it is enclosed, and artific ial heat is provided for protection, this does not waive the above requirements for moisture for curing. The c ontractor may use steam for heating and to produce an adequate supply of moisture within the enclos ure.
7.The contractor may leave forms in place instead of using burla p or membrane curing.
502.3.8 2.2 Substructures
1.Cure concrete footings, not backfilled upon form removal, and the exposed surfaces of backfilled footings as specified in 502.3.8.1 or by submersion, if the enginee r approves. If necessary to re move wetted burlap to allow form setti ng, keep the exposed concrete surface thoroughly damp.
502.3.8 2.3 Decks
1.For structures under 100 feet in length, cure the concrete in decks, medians, and sidewalks for at least 7 days with polyethylene-coated bu rlap or other coated material conforming to 501.2.9 . As soon as the concrete sets sufficiently to s upport the covering, place the c oated burlap with the coated side up; or perform an initial cure of the co ncrete by using wetted burlap for at least 12 hours and then apply the coated burlap to a thoroughly we tted concrete surface. Place ea ch strip or sheet of coated burlap so that it overlaps the preceding sheet by at least 12 inches. Secure the coated burlap covering in place. Ensure adequate moisture is present on the surface of the floor , wearing surfaces, or sidewalks beneath the curing material for the 7-day curing period.
2.For Structures 100 feet or great er in length, cure the concret e in decks, medians, and sidewalks by the following method. Begin curing the horizontal concrete surfaces by fogging within 15 minutes of finishing and tining. Apply the fog or fine water spray so that no water marks re sult and no mortar washes from the concrete surface . Keep the concrete surface continuously wet by fogging until applying the burlap strips to the finished concrete. Wet the bu rlap immediately afte r placement. During the first day, until placing the soaker hose system, keep the b urlap continuousl y wet. Through the remainder of the curing period, k eep the burlap continuously wet with soaker hoses hooked up to a continuous water source. Inspec t the burlap on a daily basis to ensure that the enti re surface is moist. If necessary, alter the soaker h ose system as needed to ensure the entire surface is moist. Do not use white polyethylene sheeting or p lastic coated burlap blankets. Continue moist curing at least 7 days.
502.3.8 2.4 Parapets
1.Cure concrete in the inside faces of railings and parapets by covering with wetted burlap immediately after form removal and surface finish application. Keep the bur lap thoroughly wet for at least 4 days; or by covering for the same period with thoroughly wetted polyethy lene-coated burlap conforming to
501.2.9 .
2.Cure concrete in the outside fa ces of railings, parapets, exte rior girders, and si milar parts of the structure by one of t he following methods: Effective with the December 2018 Letting 226 2019 Standard Spec ifications 1. Apply impervious coating cu ring material immediately after removing the forms and applying the required surface finish. 2. Cover with wetted burlap imm ediately after form removal and applying the required surface finish and keeping the burlap thoroughly wet for at least 4 days. 3. Cover for at lea st 4 days with thoroughly wetted polyethyle ne-coated burlap conforming to 501.2.9.
3.Secure coverings along all edges to prevent moisture loss.
502.3.9 Cold Weather Protection
502.3.9 1 General
1.Maintain the quality of the conc rete placed in cold weather. P rovide the protection necessary to prevent concrete freezing until it develops sufficient strength to conform to the opening criteria specified in 502.3.10 . Remove and replace frozen or frost damaged concrete at no exp ense to the department.
2.Unless the engineer directs otherwise, protect concrete under both of the following conditions: 1. The air temperature is 40 F or less. 2. The air temperature is predicted to be 40 F or less within 24 hours.
3.Ensure that forms, reinforcem ent, base, and subgrade are free of ice, snow, and frost during pouring. If the atmospheric temperature is below 40 F, preheat the inter ior surfaces of forms, all reinforcement, and the concrete surface adjac ent to the pour to 40 F or higher .
4.Adjust forms or insulation, as necessary, to control the tempe rature of the concrete. Unless the engineer allows otherwise, ensur e the temperature of the concrete does not exceed 120 F, or fall below 40 F during the protection period.
502.3.9 2 Mixing
1.Heat the mixing water, aggregat es, or both under both of the f ollowing conditions: 1. The air temperature is 40 F or less at the time of mixing o r placement. 2. The air temperature is predicted to be 40 F or less within 24 hours following placement.
2.During concrete placement, ensur e the mixed concrete temperatu re is not less than 50 F or more than 80 F, unless otherwise directed.
3.Do not heat the cement, or add salt or other chemicals to the mix to prevent freezing.
502.3.9 3 Heating
1.Protect exposed concrete surfaces within a heated housing from drying and carbonation throughout the curing period by the impervious coating method or the imper vious sheeting method specified in
502.3.8 .
2.If heated housing is r equired before plac ing concrete, heat th e housing sufficiently before placing the concrete to ensure a temperature of the forms and reinforcing s teel of not less than 40 F. Ensure a reasonably uniform temperature throughout the enclosure.
3.If the engineer allows, the contra ctor may protect footings by completely and continuously submerging in water inside the cofferdam. 502.3.9.4 Temperature Records
1.Take temperature readings with in the enclosure at necessary ti mes to show the true temperature conditions that the concrete is subjected to. At a minimum, pro vide high/low thermo meters that retain the minimum and maximum temperat ure readings for each measureme nt period. Provide facilities suitable to the engineer to verify the temperature inside and o utside the insulation, and within the mass of the concrete at various l ocations in the unit. Make tem perature recordings at least every 24 hours. Make outside air temperat ure recordings at the same time making the recordings within the enclosure. Provide a copy of the temperature record to the engi neer at the close of each day's work.
502.3.9 5 Cessation of Heating or Cold Weather Protection
1.At the end of the heating or cold weather protection period, g radually reduce the temperature within the enclosure to avoid a sudden temperature c hange of the new concrete. Make this decrease by loosening the forms and other ins ulating layers in a manner to allow the whole mass of concrete to gradually approach the outside air temperature at the end of th e curing period. Ensure the average rate of decrease does not excee d 5 F in any hour, or 40 F in any 24-hours, until reaching the outside air temperature. Allow the concrete surface to dry while equalizing the temperatures. 502.3.9.6 Bridge Decks
1.Protect concrete in bridge decks as specified for structural m asonry, and except for parapets and similar pours, according to the following requirements: Effective with the December 2018 Letting 227 2019 Standard Spec ifications 1. Do not place concrete for br idge decks or other superstruct ure elements when t he national weather service forecast for the constr uction area predic ts temperatures to fall below 32 F within 24 hours, unless the engineer specifically allows or requires in writing. 2. Protect the underside of the deck by housing and heating wh en the national weather service fo recast for the construction area predicts temperatures to fall below 20 F during the cold weather protection period.
502.3.10 Applying Loads to Concrete
502.3.10 1 Opening to Service
502.3.10 1.1 General
1.Maintain moisture, temperature , and physical protection for co ncrete until it develops sufficient strength to open it to service . The engineer will use the same criteria to allow the opening of structural masonry concrete items to service as is used to allow the openi ng of bridge superstructures to traffic.
2.The engineer will allow the cont ractor to open bridge superstr uctures or other structural masonry items to construction and public traffic when the concrete attains a verified compressive strength of 3500 psi. Without compressive strength information, the engineer may allo w the contractor to open the affected structural masonry after the fo llowing minimum times as adjuste d for concrete surface temperature. APPLICATION EQUIVALENT CURING DAYS High early strength concrete 4 General purpose concrete: grade A 5 General purpose concrete: grades A-FA, A-S, A-T, A-IS, A-IP, an d A-IT 7
3.The equivalent curing day is bas ed on a daily average concrete surface temperature of 60 F. Calculate the daily average concrete surfa ce temperature by taking the av erage of the high and low temperatures at the least favor able location of the affected co ncrete unit, as verified by the engineer, for each day. If this daily average concrete surface temperatur e falls below 60 F, then equivalent curing days accumulate at a reduced rate. Use the following gui delines to calculate equivalent curing days; for a daily average concre te surface temperature of: 1. 60 F or more; accumulate one equivalent curing day per cale ndar day. 2. 40 to less than 60 F; accumulate 0.6 e quivalent curing day per calendar day. 3. Less than 40 F; no curing credit is accumulated.
502.3.10 1.2 Exceptions
502.3.10 1.2.1 General
1.If the contract prescribes a specific wet curing period, do no t open to service until after wet curing is complete and the strength or equi valent curing day requirements are met.
2.The contractor may conduct cons truction operations on concrete not conforming to these opening criteria as specified in 502.3.10.1.2.2 and 502.3.10.1.2.3 . The engineer may suspend or delay operations that injure the surfac e or otherwise damage the conc rete. Clean the surface before allowing any traffic to use the structure.
502.3.10 1.2.2 Substructures
1.If placing footings on seals, the contractor may set the footi ng forms and place the concrete immediately after dewatering t he cofferdam and preparing the su rface of the seal. Unless the engineer directs otherwise, the contract or may set the column and wall f orms on the day after placing the concrete in the footing; and may place the concrete in columns and walls after the concrete footing for the column or wall cures for at least 24 hours over 40 F.
2.Do not apply any load of the su perstructure, or any dead load, except as specified in
502.3.10 1.2.2(1) , to concrete substructure units until the concrete in the unit cures for at least 48
hours. Do not apply loads to the beams of open-type substructur e units until after the required falsework support period.
502.3.10 1.2.3 Superstructures
1.After the concrete cures suffi ciently, the contractor may, wit h the engineer's approval, apply loads to decks that result from storing sm all articles, and operating co ncrete buggies and other necessary light equipment, if applied in a way that causes no injury to the con crete.
2.If the deck concrete conforms to 502.3.10.1.1(2) the contractor may oper ate hauling equipment as necessary to perform subsequent pours on that structure. Do not operate or park hauling equipment outside of the centerline of an ex terior girder until at least 24 hours after placing the parapet. Effective with the December 2018 Letting 228 2019 Standard Spec ifications 502.3.10.1.3 Opening Strength
502.3.10 1.3.1 General
1.Determine opening strength and pr ovide the engineer with the information required to verify that strength by one or a combination of the following methods: 1. Compressive strength testing of cylinders. 2. Maturity method.
2.The resulting opening strength, when the engineer verifies, will apply to concrete on the same project conforming to the following criteria: 1. Of the same mix design as the test location. 2. Cured under similar or more desirable conditions. 3. Placed on or before the test location.
3.If both direct compressive stren gth test results and maturity data are not available, the engineer may estimate compressive strength ba sed on test results of concrete of the same mix design placed adjacent to and under similar co nditions on the same project.
502.3.10 1.3.2 Compressive Strength Testing of Cylinders
1.Submit the compressive strength test results to the engineer f or verification. Compute the opening strength as the average of compr essive strength test results fo r 2 cylinders. If the strength of a cylinder is less than 90 percent of the re quired strength , the engineer will reject the result ing average. Field cure cylinders under conditions s imilar to those prevailing for the structural masonry unit they represent. Fabricate cylinders according to AASHTO T23 and test the cylinders according to AASHTO T22.
502.3.10 1.3.3 Maturity Method
1.Develop a strength/maturity rel ationship for each concrete mix design. Base that relationship on the strength of cylinders from concre te incorporated into the work. Submit the maturity data to the engineer for approval before placi ng more concrete using that m ix design. Develop a new strength/maturity relationship every time the mix changes or if engineer verificati on cylinder strength varies more than 10 percent from the required opening strength when tested at the calibrated opening maturity.
2.Conform to CMM 8-70 for strength/maturity relationship development, field verifica tion of the resulting curves, and maturity testing. Use a default datum temperature o f 32 F or use a mix-specific datum temperature determined according to Annex A1 of ASTM C1074 . Develop data points for the strength/maturity relationship up to 120 percent of the require d opening strength. Revise 502.3.10.1.3.3(3) to allow co ntractor determination of maturity pr obe placement based on their operations.
3.Place sensors based on contractor operations for concrete pavem ent bid items and one sensor for each 100 cubic yards of concrete placed under non-pavement bid items. The resulting maturity, after engineer verification, will apply to concrete on the same proje ct conforming to the following: 1. Of the same mix design as the test location. 2. Cured under conditions simil ar to or more favorable than th at of the test location. 3. Placed on or before the time the test location was placed.
4.Each work week provide a set o f 3 verification cylinders to th e engineer for each strength/maturity field calibration curve currently in use on the project. The engineer will designate the sa mpling location for these verification cylinders. Pr ovide 2 cylinders for compressi ve strength testing and one with a data- encrypted sensor embedded in its c enter for maturity evaluation . Cast and cure these cylinders on-site as the engineer directs and conf orming to the requirements of ASTM C31 for field curing. Deliver the 2 compressive strength cylinders to the engineer after attaining 50 percent of their opening maturity. Notify the engineer promptly when t he instrumented cylinder rea ches the opening maturity so the engineer can perform verification testing as closely as possibl e to that opening maturity level.
502.3.11 Name Plates
1.Install nameplates conforming to 506.2.4 at the locations the plans sh ow. Embed or epoxy the plate lugs in the concrete. Except fo r survey benchmarks, do not atta ch other permanent p lates or markers to a structure. 502.3.12 Bridge Seat Protection
1.Unless the contract specifies o therwise, apply a mopping of ep oxy to the top surfaces of all abutments and any piers beneath transverse joints. Effective with the December 2018 Letting 229 2019 Standard Spec ifications (2) Use the type of epoxy resin the manufacturer recommends for se aling exterior concrete surfaces, subject to the engineer’s approval.
3.Apply the epoxy before placing bearing pads or plates and befo re erecting the super structure, unless the engineer directs otherwise.
4.The contractor shall not apply r esin in wet weather, or if the surface temperature of the concrete is below 60 F unless the engineer specifically allows.
5.If applying resin, ensure the concrete surface i s dry, thoroug hly clean, and free from dust or other loose material.
6.Furnish a 2-part epoxy resin sy stem. Combine immediately befor e use and apply according to the manufacturer’s written instru ctions. If no application rate is recommended, apply the epoxy at approximately one gallon per 100 square feet.
502.3.13 Concrete Crack and Surface Sealing 502.3.13.1 Crack Sealing
1.For newly constructed bridge de cks, seal cracks visible during dry weather conditions with low- viscosity crack sealer. Conduct an initial crack survey with th e engineer within 7 days after wet curing is complete, or when the deck d ries enough to expose cracks req uiring sealing. Seal the cracks identified in the survey. Seal c rack areas only. Do not flood seal the deck unless the engineer allows as a part of overseeding with aggregate.
2.Prepare the deck by water blasting and apply crack sealer as the sealer manufacturer recommends except as follows: 1. The contractor need only wai t 7 days after completing moist curing before sealing. 2. Seal only if drying conditions have existed for the preceding 48 hours. 3. Immediately before applying sealer, direct an air blast ove r the surface to remove dust and any loose particles. 4. Seal before opening to public traffic.
3.Conduct a follow-up crack survey as late as possible, but allo wing time for sealing additional cracks and subsequently applying surface sealer, before opening to public traffic. Seal additional cracks identified in the follow-up surv ey before applying protective surface treatment.
502.3.13 2 Protective Surface Treatment
1.Apply protective surface treatment conforming to 502.2.11 to concrete decks, deck overlays, medians, and sidewalks After dec k crack sealing is completed, apply surf ace treatment to the top of new bridge decks. Do not apply to surfaces w here the contract requires sta ining or oth er treatment.
2.Clean and dry surfaces befor e applying surface treatment. Imme diately before application, direct an air blast over the surface to remov e dust and any loose particles. Ensure that application equipment is clean inside before filling and that the equipment is functioni ng properly.
3.Apply surface treatment no less than 7 days, but preferably a minimum of 21 days, after the curing period has expired. Apply according to manufacturer recommendat ions, except ensure the concrete is surface dry for a minimum of 2 consecutive days before applying . Ensure that the crack sealer is dry to the touch before applying surf ace treatment. Apply at the manufacturer's recommended rate. If application in a single coat cau ses ponding, use two lighter co ats allowed to dry between coats.
4.Complete surface treatment before opening to traffic and befor e suspending work for the winter. Do not open the bridge deck to tra ffic until the surface treatment is dry enough to sustain traffic without causing damage to the surface treatment or creating a hazard to traffic.
502.3.13 3 Pigmented Surface Sealer
1.Apply pigmented surface sealer conforming to 502.2.11 to the inside and top faces of parapets, including parapets on abutment wings. Use gray sealer unless the contract specifies a different color. Do not seal surfaces where the contract requires staining or ot her treatment.
2.Clean and dry surfaces before sealing. Immediately before seal ing, direct an air blast over the surface to remove dust and any loose par ticles. Ensure that application equipment is clean inside before filling and that the equipment is functioning properly.
3.Seal after providing the required surface finish under 502.3.7 . Conform to sealer manufacturer recommended application procedur es and coverage rate. If applic ation in a single coat causes running, use two lighter coats a llowed to dry between coats.
4.Complete sealing before opening to traffic and before suspending work for the winter. Effective with the December 2018 Letting 230 2019 Standard Spec ifications 502.3.14 Adhesive Anchors
502.3.14 1 General
1.Notify the engineer and provide t he adhesive manufacturer’s in stallation instructions to the engineer before installing anchors. Do not install anchors before 21 day s after concrete placement. Notify the engineer if reinforcement is encountered during drilling.
2.Clean holes by flushing with w ater followed by blowing with ai r until the hole is d ry and dust-free. Follow additional cleaning procedures and temperature restricti ons the adhesive manufacturer recommends.
3.Place adhesive and install rein forcing bars to the depth and of the length and bar si ze the plans show following the adhesive manufacturer's installation recommendati ons. Fill holes completely with adhesive.
4.Ensure proper installation b y one or both of the following: - Installation by or under the direct supervision of an ACI/CRSI certified installer. - Field-verified by n on-destructive pullou t testing according t o ASTM E488 .
502.3.14 2 ACI/CRSI Certified Installer
1.Have an ACI/CRSI certified insta ller install or directly super vise anchor installation. Direct supervision is directly viewing installation of 2 or more anchors per insta ller. Submit department form DT1641 to the engineer certifying that anc hor installation conforms to th e contract.
2.The engineer will verify anchor installation by periodically o bserving the contractor's installation procedures and may direct the c ontractor to perform pull-out te sting conforming to 502.3.14.3 .
502.3.14 3 Non-Destructive Pullout Testing
1.Demonstrate anchor installation and perform both installation and static tension testing according to ASTM E488 for the first 3 anchors of each rebar size installed under the contract. Do not proceed with production installation without the engineer's approval. Do not test before 28 days after concrete placement.
2.Do not allow any portion of the pull-out testing device to bea r on the concrete within a distance equal to the embedment depth the plans show. Test anchors to a proof load of 80 percent of the anchor yield strength unless the pl ans show otherwise. If an anchor fa ils, modify installation procedures or use a different anchor system and retest.
3.In addition to tests performed on the first 3 anchors of each size, test one or 5 percent of the anchors placed during production insta llation whichever is greater. Pro vide an approximate installation schedule to the engineer and imm ediately notify the engineer if a test fails. The engineer will increase testing frequency by one perc ent for each failed anchor. Submit test reports and specification sheets prescribed under ASTM E488 to the engineer upon request.
4.The engineer will verify anchor installation by periodically o bserving the contractor's installation and testing procedures and may dir ect the contractor to perform additional pull-out testing.
502.3.15 Clear Protective Coating
1.Apply a clear protective coati ng to specified areas of the sub structure.
2.Apply the coating to the concrete surface before erecting stru ctural steel. Do not apply coating at temperatures lower than the manufacturer recommends.
3.Clean the exposed vertical surfaces of the piers, and the fron t face of the abutments including the backwalls and the ends of the body wall to remove dust and dirt .
4.Apply the coating to these area s by brush or roller to give a smooth coating, completely covering the concrete. Apply the coating at the rate of one gallon per 200 s quare feet. If the coating runs or sags when applied in one coat, apply t he material in 2 approximately equal coats of thickness. Apply the second coat within 10 minutes of the first.
5.If, because of weather conditi ons, the contractor cannot apply coating to the substructure before starting steel erection, prote ct the above-mentioned areas from staining until applying the coating. Obtain the engineer's approval for the met hod of temporary prot ection.
502.4 Measurement
502.4.1 General
1.The department will measure the quantities of the various bid items that constitute the completed and accepted structure according to the contract provision for thos e bid items, in the units provided. All work included in the scope of the contract, but not listed as b id items in the propos al are incidental to the cost of the work. Effective with the December 2018 Letting 231 2019 Standard Spec ifications 502.4.2 Concrete for Bridges
1.The department will measure the Co ncrete Masonry Bridges bid i tems by the cubic yard acceptably completed. The department will not measure work or material for forms, falsework, c offerdams, unless specified otherwise, pumping, bra cing, or other incidentals nec essary to complete the work as required in these specifications.
2.If measuring floor slabs, the department will deduct the volume of the flanges of I-beams and precast concrete beams projecting into concrete floor slabs from the vo lume of the floor slab.
3.The department will deduct from t he quantity of concrete, as c omputed above, the actual volume displaced by the projection of c ast-in-place concrete piling in to the footing, pile cap, or abutment; and 0.8 cubic foot of volume for each linear foot of timber piling projecting into the footing, pile cap, or abutment. The department will meas ure this net quantity for pay ment.
4.If the contractor pours footi ngs wholly, or in part without fo rms, the department will only measure material placed within the footing dimensions the plans show.
502.4.3 Concrete for Seals
1.The department will measure Concre te Masonry Seal by cubic yar d acceptably completed. The department will only measure material the engineer orders, the plans show, or the contract specifies.
2.The department will base measurements and computations of quan tity of accepted work on the dimensions of the area and thickness of the seal the plans show , or the engineer orders. The department will deduct the volume displaced by piles, if any, f rom this quantity and the department will measure this net quantity for pay ment. If using cast in place c oncrete piling, deduct the actual volume displaced by the piling; and in the case of timber piling, deduct the quantity based on 0.8 cubic foot of volume for each linear foot of p iling projecting into or throug h the seal.
502.4.4 Preformed Elastomer ic Compression Joint Sealers
1.The department will measure the Compression Joint Sealer Prefo rmed Elastomeric bid items by the linear foot acceptably completed, measured along the centerline of the joint.
502.4.5 Expansion Devices
1.The department will measure the Ex pansion Device bid items as a single lump sum unit for each structure accept ably completed.
502.4.6 Surface Sealing
1.The department will measure the Protective Surface Treatment a nd Pigmented Surface Sealer bid items by the square yard accept ably completed, measured as the net area treated with no additional area measured where re-sealing a fter applying pavement marking as required under 646.3.1.1 .
502.4.7 Adhesive Anchors
1.The department will measure the Ad hesive Anchors bid items as each individual anchor acceptably completed. 502.4.8 Clear Protective Coatings
1.The department will measure Prot ective Coating Clear by the ga llon acceptably completed. The quantity measured equals the actual number of gallons used to t reat the abutments and piers.
502.5 Payment
502.5.1 General
1.The department will pay for measured quantities at the contrac t unit price under the following bid items: ITEM NUMBER DESCRIPTION UNIT 502.0100 Concrete Masonry Bridges CY 502.0200 Concrete Masonry Bridges HES CY 502.1100 Concrete Masonry Seal CY 502.2000 Compression Joint Sealer Preformed Elastomeric (width) L F 502.3100 Expansion Device (structure) LS 502.3200 Protective Surface Treatment SY 502.3210 Pigmented Surface Sealer SY 502.4100 - 4199 Adhesive Anchors (inch) EACH 502.4200 - 4299 Adhesiv e Anchors (bar) EACH 502.6500 Protective Coating Clear GAL Effective with the December 2018 Letting 232 2019 Standard Spec ifications (2) Perform miscellaneous work tha t the plans show or the contract specifies, but not listed as bid items, as a part of and included in the c ontract price for other bid i tems.
502.5.2 Concrete for Bridges
1.Payment for the Concrete Masonry Bridges bid items is full com pensation for providing forms and falsework; for placing, finishing, curing, protecting, and heat ing concrete; for measuring concrete opening strength, including fabric ating and testing cylinders, and evaluating maturity; for treating joints, including sealing, providing preformed joint filler and waterpr oofing; for sealing de ck cracks identified in the initial crack survey; for providing bridge seat protecti on; and for providing nameplates.
2.If the contractor pours footi ngs wholly, or in part without fo rms, the department will only pay for material placed within the footing dimensions the plans show.
3.If the engineer allows the contractor to substitute high early strength concrete to expedite the work as allowed under 502.2.2 , the contractor will bear the ad ditional costs associated with that substitution.
4.The department will pay separatel y under the Follow-Up Deck Cr ack Sealing administrative item for sealing additional deck cracks i dentified in the follow-up crac k survey at the fixed price of $3.00 per linear foot of crack acceptably sealed. The department will als o pay separately for traffic control required for the follow-up sealing operations.
502.5.3 Concrete for Seals
1.Payment for Concrete Masonry S eal is full compensation for pro viding concrete seals including forms, placing, curing, protecting, and pumping.
2.If the contract does not contain the Concrete Masonry Seal bid item and the engineer orders this work, the department will pay for this work as extra work. 502.5.4 Preformed Elastomer ic Compression Joint Sealers
1.Payment for the Compression Joint Sealer Preformed Elastomeric bid items is full compensation for providing the seal, including lubricant-adhesive. 502.5.5 Expansion Devices
1.Payment for the Expansion Device bid items is full compensatio n for providing devices.
502.5.6 Surface Sealing
1.Payment for the Protective Sur face Treatment and Pigmented Sur face Sealer bid items is full compensation for treating and sealing surfaces including surface preparation and color-matching as required. Resealing after pavement marking is incidental to the applicable pavement marking bid item under 646.5 .
502.5.7 Adhesive Anchors
1.Payment for the Adhesive Anchors bid items is full compensatio n for providing adhesive anchors; and for pullout testing including addi tional engineer-directed veri fication testing.
2.The department will pay separately for reinforcing bars under the appropriate Bar Steel Reinforcement HS bid item as specified in 505.5 .
502.5.8 Clear Protective Coatings
1.Payment for Protective Coating Clear is full compensation for providing the coating, including temporary protection, and surface preparation. Effective with the December 2018 Letting 233 2019 Standard Spec ifications Section 503 Prestressed Concrete Members
503.1 Description
1.This section describes fabricating, furnishing, transporting, and erecting prestressed concrete girders, or other prestressed concrete members.
2.These specifications provide fo r prestressing concrete members by the pretensioni ng method. In this method, stress the reinforcing tendons initially, then place an d cure the concrete and release the stress from the anchorages to the concrete after developing spe cified concrete strength.
503.2 Materials
503.2.1 General
1.Furnish materials conforming to the following: Bar steel reinforcement ................................................................................................................................... 505
2.Use galvanized or epoxy-coated steel, stainless steel, or non- metallic materials for hardware incorporated into the finished structure.
503.2.2 Concrete
1.Furnish concrete as specified in 501. If the design ultimate stress, f' c, the plans show is 8000 psi or higher for a prestressed concrete I-type girder, extend 28-day strength requirements within 503 for that girder to 56 days.
2.Ensure concrete attains a minimum 28-day compressive strength of 6000 psi for prestressed I-type girders. Base tests on 6-inch b y 12-inch cylinders, or 4-inch b y 8-inch cylinders, provided the engineer develops and approves a correlati on factor. Mold concrete cylin ders in steel or plastic molds. Cure concrete cylinders according to AASHTO T23, except cure the cyl inders with the member until release strength is obtained, then cure the cylinders according to AASH TO T23. Maintain laboratory facilities and equipment according to AASHTO M201. Make 3 cylinders for ea ch line of prestressed members poured and test each cy linder according to AASHTO T22. Calibrat e cylinder-testing equipment at least annually according to AASHTO T67. Average the strengths of the 2 cylinders with the highest test results for each line and use the average to determine complian ce with the 28-day strength requirement. Ensure that neither of the 2 cylinders with the highest test results h as a strength less than 10 percent below the required strength.
3.Instead of the above acceptance procedure, the engineer will a llow early acceptance of the prestressed units, before the 28-day test, if 2 successive laboratory tests on standard test specimens, cured continuously with and in the same manner as the units, in dicate compressive strength in excess of the required 28-da y strength. Test the 28-day strength cylin ders and record the results to maintain continuity of the contractor's quality control records.
4.Have an HTCP-certified PCC Technician I sample concrete, perfo rm fresh concrete testing, and fabricate and cure cylinders. Hav e an HTCP-certified Concrete S trength Tester, working in a department-qualified laboratory, perform cylinder and core comp ression tests. Determine the compressive strength in psi fo r each cylinder according to AASH TO T22. Test each cylinder to failure. Use a compression machine that automatically records the date, time, rate of loading on a load vs. time plot, and maximum load for each cylinder. Include a printo ut of this information with the strength documentation for each cylinder tested. Notify the engineer imm ediately if concrete cylinder compressive strengths are less than the required 28-day strength. Keep neatly documented records of all cylinder testing on the day of the test and make them avail able to the engineer.
5.Furnish prestressed concrete me mbers cast from air-entrained c oncrete, except I-type girders may use non-air-entrained concrete. Use type I, IL, IS, IP, IT, II, or III cement. The contractor may replace up to 30 percent of type I, I L, II, or III cement with an equal weight of fly ash, slag, or a combination of fly ash and slag. Ensure th at fly ash conforms to 501.2.6 and slag conforms to 501.2.7 . Use only one source and replacement rate for work under a single bid item. U se a department-approved air- entraining admixture conforming to 501.2.2 for air-entrained concrete. Use only size No. 1 coarse aggregate conforming to 501.2.5.4 .
6.The contractor shall determine pr oportions for the mix within the following limitations: Water cementitious mat erial ratio, w/cm ....................... ............................................................... .... 0.45 or less[1] Cementitious mat erial content ................................. ............................................ 610-800 pounds per cubic yard Air content: Prestressed I- type girders .................................... ........................................................ 6.0 pe rcent maximum Other com ponents .............................................. ............................................................... ... 4.5 - 7.5 percent Slump ......................................................... ............................................................... .......... 8 inches maximum[2]
Referenced in this section
Concrete Bridges in other states
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Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 221–241 of 601. View official source ↗