601.1-DESCRIPTION: This work shall consist of furnishing and placing portland cement concrete for structures, and incidental construction, in accordance with these specifications and in reasonably close conformity with the lines, grades and dimensions as shown on the Plans or established by the Engineer. All concrete shall be air-entrained. Classes of concrete shall be used as indicated below unless noted otherwise on the Plans: Class A concrete shall be used in railing, cribbing, precast shapes, and for filler. Class K concrete shall be used in all sidewalks, parapets, decks, and median barriers when they are a part of the bridge superstructure. Class B concrete shall be used in all beams and girders, roadway sidewalks, columns, hammerhead piers, arch rings including ties and spandrel walls, rigid frames, box culverts, heavily reinforced abutments, retaining walls, footings, pedestals and other areas not specifically designated as to class of concrete. Class C concrete shall be used in massive footings and pedestals, m assive pier shafts, gravity walls and, in general, for non-reinforced or lightly reinforced concrete. Class D concrete shall be used as unformed and non-reinforced concrete for backfilling of any excavated pockets or voids on which footings are to be located. Class H concrete shall be used for bridge decks and other bridge elements when designated in the plans. Class DC concrete shall be used in rock socketed drilled shafts. If the Contractor so elects, the Engineer may permit the use of a higher class concrete than the particular class designated for the work, in which event the higher class concrete shall meet the Specifications applicable without additional compensation. If the contractor uses a higher class concrete, and the strength specimens do not meet the minimum strength requirement of that higher class concrete, no penalty will be applied, provided that the strength specimens exceed the minimum strength requirement of the concrete that was originally designated for the work. When called for on the Plans, an admixture of water-reducing retarder shall be added to all concrete so specified. A retarder may be used in other concrete at the Contractor's option. The work will be accepted in accordance with these Specifications and the applicable requirements of sections 105, 106, and 109. All classes of concrete shall be designated as modified when using increased design strengths. All classes of concrete shall be designated as architectural when using additional formwork as shown in Section 601.8.10. A hydration control stabilizing admixture may be used at the Contractor's option provided that the conditions in section 601.7 are met. 601.2-MATERIALS: Materials shall meet the requirements specified in the following Sections or Subsections of Division 700: Class H Concrete Requirements: The total concrete constituents shall contribute less than 0.10% water soluble chloride ion by weight of cement. The Contractor shall use only one brand and/or source for any concrete constituent. The Contractor shall obtain a written statement from the manufacturer of the silica fume admixture that confirms the compatibility of the material combination and the sequence in which they are combined. The written statement, along with the results of all required tests, shall be furnished to the Engineer prior to the pre-pour meeting. MATERIAL SECTION OR SUBSECTION Accelerating Admixtures 707.13 Air-Entraining Admixtures 707.1 Boiled Linseed Oil 711.2 Coarse Aggregate 703 Concrete Sealer 707.12 Curing Materials 707.6-707.10 Epoxy Resin Protective Coating 707.11 Fine Aggregate** 702.1 Hydration Control Stabilizing Admixtures 707.15 Joint Filler (Substructure)**** 708.1.2 Joint Filler (Superstructure)***** 708.1.1 Petroleum Spirits (Mineral Spirits) 711.5 Portland Cement* 701.1, 701.3 Pozzolanic Additives*** 707.4 Specific Performance Admixtures 707.17 Supplementary Cementitious Materials (SCM)*** 707.4 Water 715.7 Water Reducer 707.3 Water-Reducing, Accelerating Admixtures 707.14 Water-Reducing, Set-Retarding Admixtures 707.2 * It is normally intended that the product of only one mill or of any one brand or type of Portland cement be used on any one structure. ** Only siliceous sand shall be used as fine aggregate in bridge deck wearing surfaces. *** The use of a Supplementary Cementitious Material (SCM) will not be permitted when a blended hydraulic cement is used. For the purposes of cement material substitution with SCMs, Type IL cement shall not be treated as a blended cement, and a SCM may be used with Type IL cement. Unless otherwise permitted by the Engineer, only one source of a SCM shall be used in any one structure. **** Joint filler for vertical joints in the substructure shall be in accordance with Section 708.1.2. ***** Preformed joint filler for vertical joints in the superstructure shall be sponge rubber in accordance with Section 708.1.1. Shipping and Storage of Cement: Cement shall be shipped from pretested and approved bins at the mill or distribution terminals. Cement stored by the Contractor for a period longer than 90 days shall be retested before being used in the work. Cement failing to meet any of the specified requirements at any time prior to incorporation into the work will be rejected and shall be removed from the work. Cements of different brands, types, or from different mills shall be stored separately. Shipping and Storage of SCMs: SCMs shall be shi pped from only those sources approved by the Division. Bulk SCMs shall be stored at the job site in weatherproof bins. SCMs from different sources or from different lots at the same source shall be stored separately. CONSTRUCTION METHODS 601.3-PROPORTIONING: The proportions for any concrete designated as modified shall be submitted by the Contractor to the Engineer for approval. The Design 28 -Day Compressive Strength shall be as shown in the plans . The contractor’s mix design shall utilize Table 601.3.1, except the Target Cement Factor may be revised to obtain the modified strength. Class H concrete shall consist of a homogeneous mixture of cement, fine aggregate, coarse aggregate, silica fume admixture, fly ash or slag cement, chemical admixtures, and water. Establishment of mixture proportions shall be coordinated with the manufacturer of the silica fume admixture. Design mixture testing for Class H concrete shall be in accordance with MP 711.03.23 and shall include air content, slump, compressive strength, and rapid chloride permeability tests. For establishment of mixture proportions, rapid chloride permeability tests shall be made on representative samples prepared and tested in accordance with AASHTO T 277. The rapid chloride permeability test specimens shall be tested at an age of 90 days (or at any time prior to 90 days), and the results of this test shall not exceed 750 coulombs. Specimens shall be moist cured for 56 days prior to the start of specimen preparation unless specimens are to be tested prior to 56 days, in which case the specimens shall be moist cured until the time of test. The 28-day compressive strength of the test mix that satisfies the 750 coulomb threshold shall be used as the basis for acceptance of Class H concrete per Section 601.4.5. The cost of all test mix requirements shall be considered incidental to the cost of Class H concrete. For establishment of mixture proportions, as an alternative to the curing methods for rapid chloride permeability testing outlined in the previous paragraph, specimens may be moist cured for 7 days in accordance with ASTM C192, then cured for 21 days in lime-saturated water at 100.0 ± 3.5 °F, then tested at an age of 28 days. This method of curing shall be noted as the accelerated RCPT curing method. 601.3.1-Mix Design Requirements: Prior to the start of construction, the Contractor shall design and submit to the Engineer for approval the proportion of materials, including admixtures, to be used which will result in a workable concrete having the applicable properties enumerated below, including those of Table 601.3.1A. A mix design prepared in accordance with MP 711.03.23, shall be required for each class of concrete to be used in the work. The mix design shall be accompani ed by a statement giving the source of materials and certified test data from a Division approved laboratory demonstrating the adequacy of the mix design. The Contractor shall notify the Engineer of any change in the source of materials or the addition of admixtures during the progress of the work, since such change may necessitate a new mix design. The Contractor shall also state the Ā value of the fine aggregate and the Ā value of the combined grading of the coarse aggregate, fine aggregate, and cement used in the mix design. Each mix design shall remain approved for a period of three years from the date of approval, after which the mix design may be re-approved for an additional time period. The guidelines for this re-approval process are set forth in MP 711.03.23. Approved Hydration Control Stabilizing Admixtures, as defined in Section 707.15, which are designed to stop the hydration of cement in a concrete mix, enabling an extension to the allowable discharge time from a truck mixer as outlined in Section 601.7, may be added to an existing approved concrete mix design in accordance with the procedures outlined in MP 711.03.23. TABLE 601.3.1A Class of Concrete Design 28 Day Compressive Strength Target Cement Factor Maximum Water Content Standard Size of Coarse Aggregate*** Entrained Air Pounds per Square inch lbs./c.y.* lb. of water / lb. of cement ** Number Percent A 3500 682 0.51 7, 78, or 8 7.5 K 4000 658 0.44 57, 67 7.0 B 3000 564 0.49 57, 67 7.0 C 2500 494 0.58 57, 67 6.0 D 2000 400 0.62 57, 67 5.5 H 4000 See Table 601.3.1C 0.40 57,67 6.5 DC 4500 705 0.44 7, 78, 8 6.0 * An equal mass of a SCM may be substituted for Portland cement up to the maximum amount in Table 601.3.1B. Only one SCM is permitted in a mix design, except for Class H concrete. The target cement factor of Class H concrete shall consist of Option 1 or Option 2 from Table 601.3.1C. The Contractor may choose either option. ** When using a SCM, masses of these materials shall be considered as cem ent for purposes of establishing maximum water content. *** A number 67 coarse aggregate may be used in Class DC concrete, provided the Engineer approves the use of that size aggregate for the specific project on which it is to be used. That approval will depend on the minimum spacing of the reinforcing steel in the drilled shaft foundation. TABLE 601.3.1B Material Class of Concrete Quantity Fly Ash All Classes Except H 20% Slag Cement All Classes Except H 50% Silica Fume All Classes Except H 8% TABLE 601.3.1C Option Cement Fly Ash Slag Cement Silica Fume 1 470 lbs. 132 lbs. 30 lbs. 2 423 lbs. 195 lbs. 30 lbs. MP 711.03.26 shall be used to control the cement factor in all classes of concrete except Class H. The Contractor may develop mix designs with a reduced target cement factor as indicated in Table 601.3.1D in lieu of Table 601.3.1A, provided the aggregates used in those mix designs meet the requirements for optimized aggregate gradation in Section 601.3.2.4. 1. The Ā requirements will not apply for mix designs that use optimized aggregate gradation. TABLE 601.3.1D Class of concrete Design 28 Day Compressive Strength Target Cement Factor Maximum Water Content Nominal Maximum Aggregate Size Entrained Air Pounds per Square inch lbs./c.y. Note 1 lb. of water/lb. of Note 2cement Inches Percent A 3500 642 0.51 ½ 7.5 K 4000 618 0.44 1 7.0 B 3000 524 0.49 1 7.0 C 2500 454 0.58 1 6.0 D 2000 360 0.62 1 5.5 H 4000 See Table 601.3.1E 0.40 1 6.5 DC Note 3 4500 665 0.44 ½ 6.0 Note 1 An equal mass of a SCM may be substituted for Portland cement up to the maximum amount in Table 601.3.1B. Only one SCM is permitted in a mix design, except for Class H concrete. The target cement factor of Class H concrete shall consist of Option 1 or Option 2 from Table 601.3.1E. The Contractor may choose either option. Note 2 When using a SCM, masses of these materials shall be considered as cement for purposes of establishing maximum water content. Note 3 Nominal maximum aggregate size of 3/4 inches may be used in Class DC concrete, provided the Engineer approves the use of that size aggregate for the specific project on which it is to be used. That approval will depend on the minimum spacing of the reinforcing steel in the drilled shaft found ation. TABLE 601.3.1E Option Cement Fly Ash Slag Cement Silica Fume 1 440 lbs. 127 lbs. 25 lbs. 2 397 lbs. 186 lbs. 25 lbs. 601.3.1.1-Mix Design Using Potentially Reactive Aggregate: Alkali-Silica Reaction (ASR) is a reaction between the alkali hydroxide in concrete pore solution and reactive forms of silica in the aggregate. The reaction forms a gel that swells when moisture is present and may cause deleterious expansion within the concrete. The Division will sample aggregate according to MP 700.00.06 and test fine aggregate and coarse aggregate in accordance with AASHTO T 303 to determine the reactivity class of aggregate. The reactivity class for each aggregate source will be liste d on the MCS&T web page under Division Approved Source/Product Listing (APL) for aggregate. If the reactivity class of an aggregate Source is not listed on the APL, the Division will test fine and coarse aggregate from the Source, in accordance with AASHTO T 303, to determine the reactivity class of the aggregate prior to its use on any WVDOH project. If one or both of the aggregates (coarse or fine) used in a concrete mix are reactive (R1, R2 or R3), preventive measures are required as specified in section 601.3.1.1.1.4. The Division will test Aggregate Sources on a 3-year cycle in accordance with AASHTO T 303. Aggregate Suppliers may have their fine aggregate and coarse aggregate tested in accordance with ASTM C1293 at a Division approved lab (an AASHTO accredited Lab, accredited for ASTM C1293) at the Aggregate Supplier’s expense. The sampling and shipping of all aggregate shall be witnessed by a representative of the Division. Aggregate Suppliers may also submit results of ASTM C1293 tests which were performed by another State DOT lab. The results of ASTM C1293 testing and the resulting determination of the reactivity class of aggregate shall supersede the reactivity class of aggregate, as determined by the Division, when tested in accordance with AASHTO T 303. ASTM C1293 test will be considered valid for 5 years from the date of testing. This requirement applies to all permanent concrete structures on WVDOH projects. 601.3.1.1.1-Selecting Preventive Measures For ASR: The level of prevention shall be determined by considering the classes of concrete, precast concrete member, prestressed concrete member, the degree of aggregate reactivity and the level of alkalis from the Portland cement. The different levels of prevention are shown in Table 601.3.1.1.1.3. 601.3.1.1.1.1-Aggregate Reactivity: The degree of ASR reactivity of an aggregate will be determined as outlined in 601.3.1.1. Aggregate-reactivity classes are given in Table 601.3.1.1.1.1 If the coarse and fine aggregates in a mix design are of different reactivity classes, the level of prevention shall be selected for the most reactive aggregate type in the mix. TABLE 601.3.1.1.1.1 Classification of Aggregate Reactivity Aggregate- Reactivity Class Description of Aggregate Reactivity 14-Day Expansion when tested in accordance with AASHTO T 303, % 1-Year Expansion when tested in accordance with ASTM C1293 R0 Non-Reactive ≤ 0.10 ≤ 0.04 R1 Moderately Reactive > 0.10 to ≤ 0.30 > 0.04 to ≤ 0.12 R2 Highly Reactive > 0.30 to ≤ 0.45 > 0.12 to ≤ 0.24 R3 Very Highly Reactive > 0.45 > 0.24 601.3.1.1.1.2-Level of ASR Risk: Determine the level of ASR risk occurring in a structure by considering the aggregate reactivity class in Table 601.3.1.1.1.2. TABLE 601.3.1.1.1.2 Aggregate- Reactivity Class R0 R1 R2 R3 Level of ASR Risk Risk Level 0 Risk Level 1 Risk Level 2 Risk Level 3 601.3.1.1.1.3-Level of Prevention: The level of prevention required is determined from Table 601.3.1.1.1.3 by considering the risk of ASR from Table 601.3.1.1.1.2 in different classes of concrete, precast concrete member and prestressed concrete member (Section 603). TABLE 601.3.1.1.1.3 Determining the Level of Prevention Level of ASR Risk Classes of Concrete Precast Concrete Member Prestressed Concrete Member D A, B, C, K, H, DC Risk Level 0 V V V Risk Level 1 W X Y Risk Level 2 X Y Z Risk Level 3 Y Z See footnote** ** It is not permitted to construct prestressed concrete members (Section 603) with Aggregate Reactivity Class of R3. Measures must be taken to reduce the level of risk in these circumstances by selecting the aggregates only from the Reactivity Classes of R0, R1, or R2. 601.3.1.1.1.4-Requirements for Various Prevention Levels: These requirements shall apply to all classes of concrete except Class H. The prevention levels for Class H concrete is specified in section 601.3.1.1.1.5. 601.3.1.1.1.4.1-Prevention Level V: No special measures need to be taken for prevention level V. 601.3.1.1.1.4.2-Preventions Level W, X and Y : If it is determined that prevention level W, X, or Y is required, there are two options for prevention as follows: Option 1: Limiting the Alkali Content of the Concrete: Table 601.3.1.1.1.4.2a prescribes maximum permissible concrete alkali contents in a concrete mix. The alkali content of concrete is calculated on the basis of the alkali contributed by the Portland cement alone. TABLE 601.3.1.1.1.4.2a Maximum Alkali Contents in Portland Cement Concrete to Provide Various Levels of Prevention Prevention Maximum Alkali Content of Concrete (Na₂Oe) Level lb/yd³ V No limit W 5.0 X 4.0 Y 3.0 Note: The alkali content of the concrete is calculated by multiplying the Portland cement content of the concrete by the alkali content of the Portland cement. The alkali content of all approved cement sources is listed on the WVDOH list of Certified Portland Cement Mills. For example, for concrete containing 550 lb/yd³ of Portland cement, which has an alkali content of 0.82 percent Na₂Oe, the alkali content of the concrete is 550 X 0.82/100 = 4.51 lb/yd3 Na₂Oe. SCMs also contain alkalis; however, the use of SCM usually increases the amount of alkalis bound by the hydrates and thus reduces the available alkali content in the concrete. Thus, the alkalis present in SCMs do not need to be considered when calculating the alkali content of the concrete. However, the a lkali content of the SCM shall not exceed the limits given in Table 601.3.1.1.1.4.2b. The alkali content of all approved SCM source is listed on the WVDOH approved list of SCMs. Option 2: Using Minimum Supplementary Cementitious Materials (SCM) based on Level of Prevention. Utilize a minimum mass replacement level from Table 601.3.1.1.1.4.2b below. TABLE 601.3.1.1.1.4.2b Minimum Replacement Level of SCM (percentage by mass of cementitious material) Type of SCM Alkali Content of SCM* (Na2Oe) Level W Level X Level Y Fly ash** ≤3.0 15 20 25**** (Cao ≤18%) >3.0, ≤4.5 20 25**** Not Allowed Slag Cement ≤1.0 25 35 50 Silica Fume*** ≤1.0 1.2 x LBA 1.5 x LBA 1.8 x LBA * The alkali content of all approved SCM sources is listed on the WVDOH approved list of SCMs (APL). If the alkali content of an SCM source is not listed on the APL, the Division will test the SCM from the source to determine the alkali content prior to its use on any WVDOH project. ** The CaO content of approved fly ash sources is listed on the WVDOH approved list of fly ash (APL). If the CaO content of a fly ash source is not listed on the APL, the Division will test the fly ash from the source to determine the CaO content prior to its use on any WVDOH project. *** The minimum level of silica fume (as a percentage by mass of cementitious material) is calculated on the basis of the alkali (Na₂Oe) content of the concrete contributed by the Portland cement and expressed in lb/yd³ (LBA in Table 601.3.1.1.1.4.2b). LBA is calculated by multiplying the cement content of the concrete in lb/yd³ by the alkali content of cement divided by 100. For example, for a concrete containing 500 lb/yd³ of cement with an equivalent alkali content of 0.81 percent of Na₂Oe, the value of LBA = 500 x 0.81/100 = 4.05 lb/yd³. For this concrete, the minimum replacement level of silica fume for Level Y is 1.8 x 4.05 = 7.3 percent. Regardless of the calculated value, the minimum level of silica fume shall not be less than 7 percent when it is only method of prevention. Mix design with silica fume > 8% shall be reviewed and approved by the Engineer. **** Mix designs with minimum 25% of fly ash shall be reviewed and approved by the Engineer. Note: The minimum replacement levels in Table 601.3.1.1.1.4.2b are appropriate for use with Portland cements of moderate to high alkali contents (0.71 to 1.00 percent Na₂Oe). Table 601.3.1.1.1.4.2c provides recommendations for adjusting the level of SCM when the equivalent alkali content of the Portland cement is above or below this range. The replacement levels should not be below those given in Table 601.3.1.1.1.4.2b for prevention level W, regardless of the equivalent alkali content of the Portland cement. TABLE 601.3.1.1.1.4.2c Adjusting the Minimum Level of SCM Based on the Alkali Content of the Portland Cement Alkali Content (Na₂Oe)* Level of SCM ≤0.70 Reduce the minimum amount of SCM required in Table 601.3.1.1.1.4.2b by one prevention level.** >0.70, ≤1.00 Use the minimum levels of SCM required in Table 601.3.1.1.1.4.2b >1.00, ≤1.25 Increase the minimum amount of SCM required in 601.3.1.1.1.4.2b by one prevention level. >1.25 Not permitted to be used in PCC * The alkali content of all approved cement sources is listed on the WVDOH list of Certified Portland Cement Mills (APL). If the alkali content of a cement source is not listed on the APL, the Division will test the cement from the source to evaluate alkali content prior to its use on any WVDOH project. ** The SCM replacement levels should not be below those required in Table 601.3.1.1.1.4.2b for prevention level W, regardless of the equivalent alkali content of the Portland cement. Option 3: Using the Lithium Nitrate Admixture: The 30 percent (30%) aqueous solution of Lithium Nitrate Admixture meeting the requirements of Section 707.17 shall be used for all level of prevention including “Level Z” given in Table 601.3.1.1.1.3 except for Class H concrete. The dosage rat e of Lithium Nitrate Admixture shall be based upon the alkali content of cement used in a concrete mix. Calculation of lithium nitrate (LiNO 3) admixture dosage (100 percent) for mitigation without use of SCMs with a 30 percent (30%) aqueous solution of lithium nitrate. Gallons of LiNO3/yd3 = (A x B x 0.55)/100 Where: A = Pound of Portland cement per cubic yard in a concrete mix B = Percentage of Alkali content of cement used in a concrete mix Example: If the cement content of concrete is 550 lbs/yd 3 and the total alkali content of the cement is 0.82 percent (0.82%), the dosage of lithium nitrate admixture is: (550 x 0.82 x 0.55)/100 = 2.48 Gal/yd3. The water content of the mix shall be adjusted by removing 0.85 gallons of water per gallon of lithium nitrate solution. Example: Amount of water to be reduced (using the value from above example) Gal/yd3 = 0.85 x 2.48 = 2.11 Any concrete mix using a 100 percent (100%) lithium nitrate admixture dosage will be accepted without evaluation. The contractor shall evaluate the effectiveness of less than 100 percent (100%) lithium nitrate admixture in a concrete mix, alone or in combination with fly ash or slag cement or silica fume, in the reduction of expansion in accordance with ASTM C1567*, when a reactive aggregate(s) is (are) used in a concrete mix, at a Division approved lab (an AASHTO accredited Lab, accredited for ASTM C1567) at the contractor’s expense. The dosage rate shall not be less than 50 percent (50 %) when only a lithium nitrate admixture is using for evaluation and no SCMs are included in the concrete mix. The sampling and shipping of all aggregate shall be witnessed by a representative of the Division. The ASTM C1567 test results will be considered valid for 5 years from the date of testing. If both of the aggregates (coarse and fine) used in a concrete mix are reactive (R1, R2 or R3), the contractor shall evaluate the effectiveness of the lithium nitrate admixture, alone or in combination with fly ash or slag cement or silica fume for both of the aggregates separately. When the same source material** is proposed for the use both as coarse and as fine aggregate, test only a selection of the reactive fine aggr egate or reactive coarse aggregate, unless there is reason to expect that the coarse aggregate has a different composition than the fine aggregate or vice -versa. The combination of cement, lithium nitrate admixture, alone or in combination with fly ash or slag cement or silica fume, and aggregate that expands less than 0.10% at 16 days after casting will be considered as meeting the “Requirements for Various Prevention Levels (Section 601.3.1.1.1.4)” except for Class H concrete. The approved lithium nitrate admixture shall meet the requirements of Section 707.17 and will be listed as “Type S” admixture with footnote of approved admixture for ASR mitigation on the MCS&T web page under Division Approved Source/Product Listing (APL) for Type S: Special Performance. The alkali level of fly ash used in the subject mix shall not exceed 4.5%. The alkali level of slag cement used in the subject mix shall not exceed 1.00%. The alkali level of silica fume used in the subject mix shall not exceed 1.00%. Mix design shall be reviewed and approved by the Engineer. * Modify the w/c ratio of the mortar used in the ASTM C1567 test to 0.50. Replace Section 5.3 (Sodium Hydroxide Solution) of ASTM C1567 with the following: Sodium Hydroxide Solution - Each liter of solution shall contain 40.0 g of NaOH dissolved in 800 ml of water. Add 71 ml of the lithium nitrate admixture multiplied by the decimal equivalent of the lithium nitrate admixture dosage. (For example, to test a 75% lithium nitrate admixture dosage, each liter of solution will contain 0.75 times 71 ml of lithium nitrate admixture.) This mixture shall be diluted with additional distilled or deionized water to obtain 1.0 liter of solution. The volume proportion of soaking solution to mortar bars in a storage container shall be 4 ± 0.5 volumes of solution to 1 volume of mortar bars. The volume of a mortar bar may be taken as 184 ml. Include sufficient test solution to ensure complete immersion of the mortar bars. ** Same source material applies to same Limestone, Diabase, Quartzite and Basalt source. 601.3.1.1.1.4.3-Prevention Level Z: If it is determined that prevention level Z is required, limit the maximum alkali content of concrete to ≤ 3.0 lb/yd 3 plus use the minimum SCM replacement level shown for level Y in Table 601.3.1.1.1.4.2b. The mix design for Prevention Level Z shall be reviewed and approved by the Engineer. 601.3.1.1.1.5-Requirements for Various Prevention Levels for Class H Concrete: 601.3.1.1.1.5.1-Prevention Level V: No special measures need to be taken for prevention level V. 601.3.1.1.1.5.2-Prevention Level X: The contractor may choose Option 1 or Option 2 from Table 601.3.1C. The alkali content of cement shall not exceed 1.25%. The alkali level of fly ash shall not exceed 4.5% in option 1. The CaO of the fly ash must be limited to a maximum of 18% in option 1. The alkali level of slag cement shall not exceed 1.00% in option 2. The alkali level of silica fume shall not exceed 1.00% in option 1 and option 2. 601.3.1.1.1.5.3-Prevention Level Y: The contractor may choose Option 1 or Option 2 from Table 601.3.1C if the alkali content of cement does not exceed 1.00%. The alkali level of fly ash shall not exceed 4.5% in option 1. The CaO of the fly ash must be limited to a maximum of 18% in option 1. The alkali level of slag cement shall not exceed 1.00% in option 2. The alkali level of silica fume shall not exceed 1.00% in option 1 and option 2. 601.3.1.1.1.5.4-Prevention Level Z: The contractor may choose Option 1 from Table 601.3.1C if the alkali content of cement does not exceed 1.00% and the alkali level o f fly ash does not exceed 3.00%. The contractor may also choose Option 1 from Table 601.3.1C if the alkali content of cement does not exceed 0.85% and the alkali level of fly ash does not exceed 4.5%. The CaO of the fly ash must be limited to a maximum of 18%. The contractor may choose Option 2 from Table 601.3.1C if the alkali content of cement does not exceed 0.85%. The alkali level of slag cement shall not exceed 1.00%. The alkali level of silica fume shall not exceed 1.00% in option 1 and option 2. 601.3.1.1.1.6-Evaluation of the effectiveness of SCM to prevent deleterious expansion: The contractor may evaluate the effectiveness of an SCM in the reduction of expansion in accordance with ASTM C1567*, when a reactive aggregate(s) is (are) used in a concrete mix, at a Division approved lab (an AASHTO accredited Lab, accredited for ASTM C1567) at the contractor’s expense. The sampling and shipping of all aggregate shall be witnessed by a representative of the Division. ASTM C1567 test will be considered valid for 5 years from the date of testing. If both of the aggregates (coarse and fine) used in a concrete mix are reactive (R1, R2 or R3), the contractor shall evaluate the effectiveness of SCM for both of the aggregates separately. When the same source material** is proposed for the use both as coarse and as fine aggregate, test only a selection of the reactive fine aggregate or reactive coarse aggregate, unless there is reason to expect that the coarse aggregate has a different composition than the fine aggregate or vice-versa. The combination of cement, SCM and aggregate that expand less than 0.10% at 16 days after casting will be considered as meeting the “Requirements for Various Prevention Levels (Section 601.3.1.1.1.4)” except for Class H concret e. The evaluation with the higher percentage of SCM replacement shall be selected for the minimum replacement level of SCM for prevention level in a mix design using potentially reactive aggregate. When more than one mix design, for the same Producer/Sup plier, is submitted for evaluation, only one evaluation of the effectiveness of an SCM in the reduction of expansion in accordance with ASTM C1567 testing data, as outlined in paragraphs first through four of this sub -section, will be required for that ent ire group of mix designs (except Class H) if all of the mix design in that entire group of mix designs have the same combination of cement, SCM and aggregate sources. The alkali level of fly ash shall not exceed 4.5%. The alkali level of slag cement shall not exceed 1.00%. The alkali level of silica fume shall not exceed 1.00%. Mix designs with minimum 25% of fly ash shall be reviewed and approved by the Engineer. Mix design with silica fume > 8% shall be reviewed and approved by the Engineer. * Modify the w/c ratio of the mortar used in the ASTM C1567 test to 0.50. ** Same source material applies to same Limestone, Diabase, Quartzite and Basalt source. 601.3.2-Field Tolerances and Adjustments: 601.3.2.1-Consistency: Concrete shall have the consistency which will allow proper placement and consolidation in the required position. Every attempt shall be made to obtain a uniform consistency. The optimum consistency for various types of highway structures shall be as indicated in Table 601.3.2. Concrete for any “Slump Test” shall be deposited in a manner and location that excludes the effects of vibrations caused by traffic and concrete placement operations. An approved Type F or Type G admixture may be used to increase the consistency and improve the workability of the concrete as long as the requirements of section 707.2.2.1 or section 707.3.2.1 are met. When an admixture is used for this purpose, it m ay be referred to as a superplasticizer. No more than a total of two additions of a superplasticizer shall be permitted in any one batch of concrete. If a superplasticizer is used at the batch plant, then only one field addition is permitted. The total quantity of the superplasticizer shall not exceed the manufacturer’s recommended dosage rate. Upon addition of a superplasticizer at the job site, the mixing drum shall be turned for a minimum of 60 revolutions or 5 minutes at mixing speed to establish a workable mixture of uniform composition and consistency. If a second job site addition of superplasticizer is used; the mixing drum shall be turned a minimum of 30 additional revolutions at mixing speed. All additions and mixing of the superplasticizer s hall be completed before placement of the concrete is started. The total number of revolutions shall not exceed 300, and the concrete shall be discharged within the time limits in section 601.7. The slump of Class H concrete shall not exceed seven (7) inches under any circumstances. When a superplasticizer is used, the optimum consistency target value may be increased by four (4) inches, but under no circumstances shall the slump exceed eight (8) inches. Acceptance tests for consistency (slump), air con tent, compressive strength, etc. shall be made after all additions and mixing of the superplasticizer. Slump tests shall be performed on every batch of concrete to which superplasticizer is added (one test before and one test after the addition of superplasticizer). The Contractor shall obtain a written statement from the manufacturer of the superplasticizer stating:
i.The manufacturer is satisfied with the compatibility of the combination of materials and the sequence in which they are combined. ii. The recommended maximum admixture dosage rate. iii. Immediately after mixing, the air content and slump shall be measured by a certified Portland Cement Concrete Inspector. This written statement from the admixture manufacturer shall be made available to project personnel before any superplasticizer is added at the job site. TABLE 601.3.2 CONSISTENCY TYPE *Optimum Consistency Inches of Slump
i.For structures which have exposed, inclined surfaces such as concrete gutters, cast in place concrete slope protection, etc., requiring low slump concrete to allow proper placement and consolidation and the maintenance of the prescribed geometry; those structures which are placed by slip form construction methods where a low slump is required to maintain the prescribed geometry; and mass nonreinforced concrete. 1 inch ii. For reinforced concrete structures which are sufficiently massive and generally have sufficient clearances to allow the access of workers into the immediate area of concrete placement, such as bridge piers, column and abutment footings; piers, large columns, and other similar type structures into which workers may enter for the purpose of placing and consolidating the concrete. 2 inches iii. a. For reinforced concrete structures which are not easily accessible for spading and vibrating and offer a fair degree of difficulty in the placement and consolidation of the concrete, such as pier caps and abutments, beams and girders, box culverts, miscellaneous structure footings and other slab type structures, wall or vertical sections 8 inches or greater in width with one line of reinforcement or 12 inches or greater in width with two lines of reinforcement. 3 inches
b.For bridge decks 2 ½ inches iv. For structures which are inaccessible to workers and generally offer a considerable degree of difficulty in the placement and consolidation of the concrete, such as long slender columns and thin-walled 3 ½ sections less than 8 inches thickness. 3 ½ inches
v.For structures which present peculiar conditions under which concreting must be done, such as structural steel encasement; other special structures which contain small openings through which the concrete must pass; tremie concrete which must be placed a nd consolidated into all spaces without mechanical disturbances; and other special structures which would require high consistency concrete for proper placement and consolidation. ** * If the consistency exceeds the target value plus one inch, the Contractor shall take immediate steps to reduce the slump of succeeding loads by making necessary adjustments in the mixture. The Contractor will be allowed a reasonable time for the trucks alrea dy on the road for a central mix or truck mix operation. Failure to comply will be cause for rejection of the concrete. If the consistency exceeds the target value plus 1 ¾ inches, the concrete will be rejected. ** The optimum consistency shall be that co nsistency which will allow a proper placement and consolidation of the concrete into all spaces. 601.3.2.2-Air Content: The target value of the entrained air at the point of placement shall be as shown in Table 601.3.1A. If the entrained air does not conform with the target value within plus or minus 2.5 percentage points, the Contractor shall take immediate steps to adjust the air content of succeeding loads by making necessary adjustments in the mixture. The air content shall be measured on load s already batched and enroute, as well as the first load to which any adjustments were made in batching procedures. If the air content exceeds the target value plus 3.0 percentage points the concrete shall be rejected. When the concrete is delivered in a truck mixer and the air content is less than the target value minus 2.5 percentage points the concrete shall be rejected, or the Contractor may use additional air entraining agent in an amount that is intended to achieve the target value specified. The addition is permitted under the conditions listed below. The target of the entrained air content of Class H concrete at the time of placement shall be as shown in Table 601.3.1A. If the entrained air does not conform with the target value within plus or minus 1.5 percentage points, the Contractor shall take immediate steps to adjust the air content of succeeding loads by making necessary adjustments in the mixture. If the entrained air content of Class H concrete does not conform to the target value plus 2.0 percentage points, the concrete shall be rejected. When Class H concrete is delivered in a truck mixer and the air content is less than the target value minus 2.0 percentage points, the concrete shall be rejected or the Contractor may use additional air-entraining agent in an amount that is intended to achieve the target value specified. The addition is permitted under the conditions listed below.
i.The air entraining agent is the same as used in the approved mix design and is thoroughly mixed with a minimum of 2 gallons of water. The solution will be directed to the front of the mixer. ii. The mixer is turned a minimum of 30 revolutions, at mixing speed, or the number of revolutions established in tests to comply with uniformity requirements, whichever is more. Immediately after mixing, the air content and slump shall be measured by a certified inspector or technician. An air adjustment may be attempted twice per truck. If after the second addition the specified air content is not achieved, the concrete shall be rejected. These procedures do not alter the limits placed on time to discharge, the total revolutions of the mixing drum, or the specified slump. 601.3.2.3-Yield: The approved mix design shall be subject to modification under the conditions prescribed. After the start of the first concreting operation and immediately after the specified consistency and entrained air have been established, three unit weight determinations shall be made from different batches and the average of the thre e determinations shall be considered the unit weight of the concrete. The actual yield shall be determined from the average unit weight. The design mix shall be adjusted as required to correct the actual yield to correspond to the theoretical. During the progress of the work, the actual yield shall be verified at the frequency noted in MP 601.03.50; and, if the yield, based on a single unit weight determination, should differ from the theoretical yield by more than plus or minus two percent (2%), two additional unit weight determinations shall be made, and the average of the three determinations shall be considered the unit weight of the concrete. The actual yield shall be determined from that average unit weight, and the design mix shall be adjusted as required to correct the actual yield to correspond to the theoretical yield. The Division shall perform Yield tests randomly throughout the progress of work to verify the accuracy of the Contractor’s tests. In addition to the mix design adjustments spec ified above to correct for yield, other adjustments in the design mix proportions shall be made as necessary to maintain a plastic, workable mix with suitable finishing characteristics. No change in the brands or sources of material shall be made without prior approval of the Engineer. Methods for determining -the properties enumerated above shall be in accordance with 601.4. 601.3.2.4-Total Solids Ā: The combined grading of the coarse aggregate, fine aggregate, and cement used in the structural concrete shall conform to the design mix Ā plus or minus the tolerance specified in the following table for the coarse aggregate size used. This subsection will not apply for mix designs with optimized aggregate gradation. Subsection 601.3.2.4.1 shall be used in lieu of subsection 601.3.2.4. TABLE 601.3.2.4-Total Solids Ā Coarse Aggregate Size Number Design Mix Ā Tolerance 3 or 4 0.35 57 or 67 0.25 7, 78 or 8 0.15 Ā is the value obtained by grading of the total solids (coarse aggregate, fine aggregate, and cement). The Ā shall be determined by the Contractor (in accordance with MP 601.03.51) at least once for every 50 cubic yards of concrete that are produced from the same mix design. However, not more than one Ā test (for each mix design) shall be required per calendar day as long as not more than 400 cubic yards of concrete are produced in a single day from the same mix design. In situations when more than 400 cubic yards of concrete are produced in a single day fro m the same mix design, two Ā tests shall be required (one in the AM and one in the PM) for that mix design. During any calendar week (Sunday through Saturday) in which concrete is being produced, a minimum of one Ā test shall be required (for each mix des ign from which concrete is being produced). This Ā test shall be conducted on the first day of production of that calendar week. For days on which concrete is being produced, but no Ā test is required, laboratory number 1392885 shall be used for Ā test documentation purposes. Should the moving average of any five consecutive grading tests of the total solids have an Ā outside the specified mix design tolerance limits, production shall be discontinued until appropriate corrections are made. Corrections shall be made either in the proportions of the concrete (the mix design), the gradation of the aggregates, or the storage and loading of the aggregate, as the Contractor may elect. When the small quantity work condition applies, the Ā required after 50 cubic yards of concrete production shall be performed on the day that the 50 cubic yard quantity is achieved. All concrete produced on that day (the day that the 50 cubic yard quantity is achieved) shall be represented by the previous Ā. The Ā conducted on the day that the 50 cubic yard quantity is achieved shall represent the next 50 cubic yards of concrete produced, beginning with the concrete produced on the next day of production. When, in a concrete mix, gradations tests show that the pe rcentage of material which passes the No. 200 (75 µm) sieve, exceeds the amount permitted in Sections 702.1.2 and 703.4, and provided the Engineer permits the material to remain in place and the Contractor elects to leave the material in place, then a penalty shall be applied in the manner outlined in the following paragraph. It shall be determined which material (coarse aggregate, fine aggregate, or both) caused the total material finer than the No. 200 (75 µm) sieve to exceed the specification limits as determined in Sections 702.1.2 and 703.4. The mass of the material(s) in the concrete mix (Mca, Mfa, or both, as defined in MP 601.03.51), which caused the total material finer than the No. 200 (75 µm) sieve to exceed the specification limits shall be divided by M t (as defined in MP 601.03.51). The resulting number shall be multiplied by the unit price of the concrete, as billed by the Concrete Supplier and by the quantity of non -specification concrete placed. That value shall be the penalty applied f or the use of the material which did not meet the specification requirements. 601.3.2.4.1-Optimized Aggregate Gradation: The optimized aggregate gradation is performed by mechanical analysis on all of the coarse and fine aggregates used in any mix design. The combined percent retained from all aggregate gradation shall conform Table 601.3.2.4.1A. The combined percent retained from all aggregate gradations in Table 601.3.2.4.1A is based on the Tarantula Curve for optimized aggregate gradation. The contractor shall determine optimized aggregate gradation in accordance with MP 601.03.53. Table 601.3.2.4.1A Sieve Size Combined % Retained 1½ in 0% 1 in ≤ 16% ¾ in ≤ 20% ½ in 4 - 20% ⅜ in 4 - 20% No. 4 4 - 20% No. 8 ≤ 12% No. 16 ≤ 12% No. 30 4 - 20% No. 50 4 - 20% No. 100 ≤ 10% No. 200 ≤ 2% Coarse Sand % Retained (No.8 to No. 30 Sieve) > 15% Fine Sand % Retained (No. 30 to No. 200 Sieve) 24% - 34% The combined aggregate gradation test shall be performed by the contractor (in accordance with MP 601.03.53) at least once for every 50 cubic yards of concrete that are produced from the same mix design. The working range on each sieve from cumulative combined percent retained from aggregate gradation shall be in accordance with Table 601.3.2.4.1B. However, not more than one combined aggregate gradation test (for each mix design) shall be required per calendar day as long as not more than 400 cubic yards of concrete are produced in a single day from the same mix design. In situations when more than 400 cubic yards of concrete are produced in a single day from the same mix design, two combined aggregate gradation tests shall be required (one in the AM and one in the PM) for that mix design. Table 601.3.2.4.1B Sieve Size Allowable variation from Combined % Retained in Design Mix Note 1 1 in ± 10% of the % retained on this sieve in the Design Mix ¾ in ± 10% of the % retained on this sieve in the Design Mix ½ in ± 10% of the % retained on this sieve in the Design Mix ⅜ in ± 10% of the % retained on this sieve in the Design Mix No. 4 ± 5% of the % retained on this sieve in the Design Mix No. 8 ± 5% of the % retained on this sieve in the Design Mix No. 16 ± 4% of the % retained on this sieve in the Design Mix No. 30 ± 4% of the % retained on this sieve in the Design Mix No. 50 ± 4% of the % retained on this sieve in the Design Mix No. 100 ± 3% of the % retained on this sieve in the Design Mix No. 200 ± 3% of the % retained on this sieve in the Design Mix Note 1 The maximum and minimum allowable % retained on each sieve size noted in Table 601.3.2.4.1A shall not be exceeded during production. During any calendar week (Sunday through Saturday) in which concrete is being produced, a minimum of one combined aggregate gradation test shall be required (for each mix design from which concrete is being produced). This combined aggregate gradation test shall be conducted on the first day of production of that calendar week. Should the moving average of any five consecutive combined aggregate gradation tests have a working range outside of the limits sets forth on Table 601.3.2.4.1B, for any of the sieve sizes listed, production shall be discontinued until appropriate corrections are made. Corrections shall be made either in the aggregate proportions in the concrete mix (the mix design), the gradation of the aggregates, or the storage and loading of the aggregate, as the Contractor may elect. When the small quantity work condition applies, the combined aggregate gradation test required after 50 cubic yards of concrete production shall be performed on the day that the 50 cubic yard quantity is achieved. All concrete produced on that day (the day that the 50 cubic yard quantity is achieved) shall be represented by the previous combined aggregate aggradation test. The combined aggregate gradation test conducted on the day that the 50 cubic yard quantity is achieved shall represent the next 50 cubic yards of concrete produced, beginning with the concrete produced on the next day of production. When, in a concrete mix, gradations tests show that the percentage of material which passes the No. 200 (75 μm) siev e, exceeds the amount permitted in Sections 702.1.2 and 703.4, and provided the Engineer permits the material to remain in place and the Contractor elects to leave the material in place, then a penalty shall be applied in the manner outlined in the following paragraph. It shall be determined which material (coarse aggregate, fine aggregate, or both) caused the total material finer than the No. 200 (75 μm) sieve to exceed the specification limits as determined in Sections 702.1.2 and 703.4. The mass of the material(s) in the concrete mix (Mca, Mfa, or both, as defined in MP 601.03.53), which caused the total material finer than the No. 200 (75 μm) sieve to exceed the specification limits shall be divided by Mt (as defined in MP 601.03.53). The resulting number shall be multiplied by the unit price of the concrete, as billed by the Concrete Supplier and by the quantity of non -specification concrete placed. That value shall be the penalty applied for the use of the material which did not meet the specification requirements. 601.4-TESTING: 601.4.1-Sampling and Testing Methods: Sampling fresh concrete AASHTO R 60 Sampling aggregate MP 700.00.06 Sieve analysis of fine and coarse aggregates AASHTO T 27 and AASHTO T 11 Slump of portland cement concrete AASHTO T 119 Note 1 Air content of freshly mixed concrete AASHTO T 152 AASHTO T 196 Unit weight/Yield of concrete AASHTO T 121 Standard Practice for Making and Curing Concrete Test Specimens in the Field AASHTO R 100 with MP 601.04.20 Compressive strength of cylindrical concrete specimens AASHTO T 22 Total moisture content of aggregate by drying AASHTO T 255 Predicting potential strength of portland cement concrete MP 711.03.31 Determination of Ā of total solids in concrete MP 601.03.51 Determination of free moisture in fine aggregate using 20 gram or 26 gram A “Speedy Moisture Tester” MP 702.00.20 Rapid Chloride Permeability Test AASHTO T 277 Note 1 When testing concrete produced by volumetric batching and continuous mixing, the consistency testing shall be delayed for approximately three to five minutes after mixing. 601.4.2-Contractor's Quality Control: Quality control of the structural concrete is the responsibility of the Contractor as designated in MP 601.03.50. The Contractor shall maintain equipment and qualified personnel, including at least one certified Portland cement concrete technician who sha ll direct all field inspection, sampling and testing necessary to determine the magnitude of the various properties of concrete governed by the Specifications and shall maintain these properties within the limits of this Specification. The Contractor’s personnel who conducts the field sampling and testing shall be a certified Portland Cement Concrete Inspector. The quality control plan designated in MP 601.03.50 shall be submitted to the Engineer at the preconstruction conference. Work shall not begin un til the plan is reviewed for conformance with the contract documents. A certified Portland cement concrete (PCC) Technician shall be present at the Concrete Supplier during all batching operations and shall directly oversee those batching operations and any subsequent necessary mix adjustments. A certified PCC technician may perform this work from an alternate remote location, provided that the PCC Technician uses District approved concrete QC batching software to directly oversee all batching operations and perform any subsequent necessary mix adjustments. The details of this remote monitoring shall be outlined in the Quality Control Plan for plant operations. The Contractor shall provide a copy of the quality control test results to the Supplier of the concrete which was tested within 48 hours of the completion of the test. Any Agency or Laboratory which tests Contractor Quality Control concrete compressive strength specimens, that may be used for acceptance by the Division, shall be evaluated by the Cement and Concrete Reference Laboratory (CCRL) and certified by the Division as meeting all the requirements of ASTM C1077 pertaining to testing concrete cylinders, as outlined in Section 4.2 of MP 601.03.50. 601.4.3-Acceptance Testing: Acceptance sampling and testing of Portland cement concrete is the responsibility of the Division, except for furnishing of necessary materials. Quality control sampling and testing performed by the Contractor may be utilized by the Division for acceptance. Strength as used in this specification, is only one indicator of the durability of the Portland cement concrete. Evaluation of structural concrete may include evaluation of the freeze-thaw durability, scaling characteristics, abrasion resistance, density and s uch other factors the Division deems appropriate. 601.4.4-Compressive Strength Tests for Acceptance: A strength test shall consist of three test specimens. Either 6” x 12” cylinders or 4” x 8” cylinders are permitted, provided the requirements of MP 711.03.23 are met. The size of the cylinders which the Contractor intends to use on each project shall be listed in the Contractor’s Quality Control Plan. The test shall be the average of the three specimens, except that if one specimen shows manifest evidence of improper sampling, molding, or testing, it shall be discarded and the remaining two strengths averaged. Should more than one specimen representing a given test show definite defects due to improper sampling, molding, or testing, the entire test shall be discarded. The maximum acceptable range of compressive strengths within a set of three cylinders is 9.5%. This range is found by multiplying 9.5% times the average compressive strength of the three cylinders. If this acceptable range is exceeded, the cylinder that varies the most from the average shall be discarded, and the remaining two cylinders shall be evaluated as outlined in the following paragraph. The maximum acceptable range of compressive strengths within a set of two cylinder s is 8.0%. This range is found by multiplying 8.0% times the average compressive strength of the two cylinders. If this acceptable range is exceeded, the entire test shall be discarded. Under no circumstances shall a compressive strength test consist of less than the average of two specimens. Compressive strength tests shall conform to the requirements of Table 601.3.1. Statistical analysis may indicate a percentage of production to be below nominal minimum design strength. Concrete represented by compressive strengths below the nominal minimum design strength of Table 601.3.1 may be removed and replaced by the Contractor. If the Contractor elects to leave the material in place, it will be evaluated as to adequacy for the use intended. All concrete evaluated as unsatisfactory for the use intended shall be removed and replaced or otherwise corrected by and at the expense of the Contractor as required in 105.3. When an evaluation indicates that the work may satisfactorily remain in place, a statistical analysis will be made of the material. If this statistical analysis indicates at least 93 percent (93%) of the material may be expected to have compressive strengths equal to or greater than that shown in Table 601.3.1 and 99.87 percent (99.87%) of the material may be expected to have compressive strengths at least one standard deviation above forty percent of the design strength (0.4f'c+σ), the work will be accepted as substantially complying with the specification requirements. If this statistical an alysis indicates that less than 93 percent (93%) of the material may be expected to have compressive strengths equal to or greater than that shown in Table 601.3.1 or less than 99.87 percent (99.87%) of the material may be expected to have compressive strengths at least one standard deviation above forty percent (40%) of the design strength (0.4f'’ c+σ), the Engineer will provide for an appropriate adjustment under the provisions of 601.15. Whenever possible, the Division ’s statistical analysis will be ba sed on a minimum of 10 cylinder test results. These results may be from the concrete item being placed, the same class of concrete on the project, or the same class of concrete from the producer. All of the cylinder test results used in this evaluation, however, must be from the same mix design. 601.4.5-Tests for Permeability Acceptance of Class H Concrete: The Contractor shall be required to compare the compressive strength test results obtained in Section 601.4.4, for Class H concrete, to the compressive strength of the approved test mix per Section 601.3. The Contractor shall also be required to fabricate six (6) rapid chloride permeability test specimens in accordance with AASHTO T 277 every time that a set of compressive strength specimens for Class H concrete is fabricated. Chloride Permeability of the in-place concrete shall be considered acceptable if the 28 -day compressive strengths obtained in Section 601.4.4 are greater than eighty percent (80%) of the 28-day compressive strength of the approved test mix. Concrete represented by compressive strengths below eighty percent (80%) of the 28 -day compressive strength of the approved test mix may be removed and replaced by the Contractor. If the Contractor elects to leave the material in place, it will be evaluated as to adequacy for the use intended. All concrete evaluated as unsatisfactory for the use intended shall be removed and replaced or otherwise corrected by and at the expense of the Contractor as required in Section 105.3. The Contractor shall also be required to fabricate six rapid chloride permeability test specimens in accordance with AASHTO T 277 every time that a set of compressive strength specimens is fabricated. These test specimens shall be moist cured until as close to the time of test as possible. If the 28-day compressive strength of the in-place concrete (obtained in Section 601.4.4) is less than or equal to eighty percent (80%) of the compressive strength of the approved test mix, these rapid chloride permeability test specimens shall be tested in accordance with AASHTO T 277, otherwise testing of these specimens is not required. When testing of these specimens is required, two test specimens shall be tested at each of the following ages: 35, 56, and 90 days. These test results shall be used by the Engineer as the basis for evaluation as to the adequacy of the material for the use intended. 601.5-EQUIPMENT AND TOOLS: 601.5.1-Field Laboratory: Field laboratory provisions shall conform to the requirements prescribed in 501.5.1. 601.5.2-Batching Plant and Equipment: 601.5.2.1-General: The batching plant shall include bins, weigh hoppers, and scales for the fine aggregate and for each size of coarse aggregate. If cement is used in bulk, a separate bin, weight hopper, and scale for cement shall be included. The cement weight hopper shall be properly sealed to preclude dusting during operation and shall be properly vented to prevent a build-up in pressure. The discharge chute shall not be suspended from the weighing hopper and shall be so arranged that cement will not lodge in it nor leak from it. When fly ash is used in the concrete a separate bin shall be included. 601.5.2.2-Bins: Bins with adequate separate compartments for fine aggregate and for each size of coarse aggregate shall be provided in the batching plant. 601.5.2.3-Scales: The scales for weighing aggregates and cement shall conform to the requirements in 109.1. Scales shall be inspected and sealed as often as the Engineer deems necessary to ensure their continued accuracy and as outlined in MP 700.00.30. The Contra ctor shall have on hand not less than ten (10) 50 lb. weights for frequent testing of all scales. 601.5.2.4-Automatic Weighing Devices: Batching plants equipped to proportion aggregates and bulk cement by means of automatic weighing devices of an approved type may be used. 601.5.2.5-Water Measuring Equipment: Water shall be measured by volume or by weight. The device for the measurement of the water shall be readily adjustable and, under all operating conditions, shall have an accuracy within one percent (1%) of the quantity of water required for the batch. 601.5.2.6-Admixture Dispenser: A positive, automatic method shall be used for adding each admixture in solution. 601.5.2.7-Aggregate Sampling: Provisions shall be made to allow a rapid sampling of the aggregates as they pass from the storage bin to the weigh hopper or as they pass from the storage bin into the conveyor feed. 601.5.3-Mixers and Agitators: Site and central mixers, truck mixers, truck agitators, and non-agitator trucks shall conform to the requirements of AASHTO M 157, except as modified. Volumetric mixers shall conform to the requirements of AASHTO M 241, except as modified. Central mixers shall be equipped with a device which will automatically lock the discharge lever when the drum has been charged and release it at the end of the mixing period. The device shall be equipped with a bell or other suitable warning device adjusted to give a clearly audible signal each time the lock is released. In case of failure of the timing device, the mixer may be used for the balance of the day while it is being repaired, providing that each batch is mixed for the specified time period. All mixers shall be cleaned at suitable intervals. The pickup and throw -over blades in the drum or drums shall be repaired or replaced when they are worn down ¾ inch or more. The Contractor shall either have available at the job site a copy of the manufacturer's design, showing dimensions and arrangements of blades in reference to original height and depth, or provide permanent marks on blades to show points of ¾ inch wear from new conditions. Holes of ¼ inch diameter near each end and at midpoint of each blade are recommended. 601.5.4-Recording T hermometer: The Contractor shall supply a continuous recording thermometer capable of recording temperatures in the 30-150° F range. It shall likewise provide a recording capability over a 24-hour continuous period, minimum. The Contractor shall provide any ancillary equipment, supplies and labor necessary for calibration of this equipment. 601.5.5-Bridge Deck Placing and Finishing Equipment: This shall include adequate hand tools for the placement of plastic concrete and for working down to approximately the correct level for the auger strike -off. A self -propelled finishing machine will be required to place and finish all concrete, except in areas inaccessible to the machine. The finishing machine shall be capable of forward and reverse mo tion under positive control. Provisions shall be made for raising the screeds to clear the screeded surface, if traveling in reverse. The machine shall be capable of placing full width, in one operation, the pours shown in the plans. The finishing machine shall be equipped with a vibrating device to consolidate the concrete, a power-driven strike-off auger, a power-driven finishing roller, and a pan float. The vibrating device shall vibrate at a frequency between 50 Hz and 115 Hz. A suffic ient number of suitable portable lightweight or wheeled work bridges shall be required and used behind the finishing operation for touch-up work, surface texturing and curing cover placement. Approved manual type screeds, metal plates equipped with electric vibrators, or handheld vibrators shall be used to consolidate and finish small inaccessible areas. The placing and finishing equipment shall be designed so that the elapsed time requirements, specified in Section 601.12.4, between discharge of the concrete and application of the wet burlap will be met. 601.6-HANDLING, MEASURING, AND BATCHING OF MATERIALS: Handling, measuring, and batching of materials for ready -mix concrete shall conform to the requirements specified in Subsection 501.7. Handling, measuring, and batching of materials for volumetric batching and continuous mixing shall conform to the applicable requirements specified in 501.7 and AASHTO M 241. When silica fume densified powder is used, the densified powder shall be weighed using an approved cement scale or standard 25 lb. or 50 lb. full bags may be substituted. Batching tolerance for the cement plus densified powder shall be 1.0%. Batching and mixing recommendations for bulk and bagged densified silica fume are provided in the Silica Fume User’s Manual which is available through the Silica Fume Association (Report Number FHWA-IF-05-016). These recommendations include procedures to be used when the Ready -Mix Supplier desires to add silica fume, which is supplied in repulpable bags, into the mix. If these recommendations are followed, and the Ready-Mix Supplier can satisfactorily demonstrate to the Engineer, by means of testing and wet -sieving a trial batch (see section 7.3.6 of the Silica Fume User’s Manual), that there are no fragments of the packaging material remaining in the mix, then the restriction in section 501.7, concerning the addition of the SCM packaging material, may be waived. The above referenced testing and wet-sieving of the trial batch shall be done on a plant-by- plant and mix -by-mix basis. When truck -mixed concrete is used, the truck which demonstrates the greatest degree of variability in the uniformity requirements, as specified in AASHTO M 157, shall be the truck which is used to produce the trial batch for testing and wet-sieving purposes. If the Ready-Mix Supplier intends to use this approach, it shall be addressed in the Plant portion of the Quality Control Plan. 601.7-MIXING: Concrete may be central -mixed, truck -mixed, or shrink -mixed as defined in AASHTO M 157 and will be designated as ready-mixed concrete. The production of ready-mixed concrete shall meet the applicable requir ements of AASHTO M 157, paragraphs ten and eleven, except as otherwise specified. Concrete for incidental construction items may be made by volumetric batching and continuous mixing as designated in ASTM C685, except as otherwise specified. Concrete produced by this method will not be permitted in bridge, box culvert, pavement, or retaining wall construction. When a truck mixer or agitator is used for transporting concrete, the concrete shall be delivered to the site of work and discharge completed withi n one and one -half hours after the addition of the cement to the aggregates. Each batch of the concrete delivered at the job site shall be accompanied by a batch ticket that contains complete batching information, including the batch weights (or batch volume, in the case of water) of all materials in that batch of concrete. In adverse weather or under other conditions contributing to quick stiffening of the concrete, or when the temperature of the concrete is 85°F or above, the time between the introducti on of the cement to the aggregates and the discharge shall not exceed one hour. When a truck mixer is used for the complete mixing of the concrete, the mixing operation shall begin within one hour after the cement has been added to the aggregate. When placing concrete at remote locations, due to excessive haul time to the site of work from the closest approved batch plant, and when discharge of the concrete within the time limits specified in the previous paragraph is not possible, or in other circ umstances when approved by the Engineer, a concrete mix that includes a hydration control stabilizing admixture may be used to extend the allowable concrete discharge time. The subject concrete mix containing this admixture must be approved in accordance with section 601.3.1, and the hydration control stabilizing admixture must be approved in accordance with section 707.15. When conditions are such that a hydration control stabilizing admixture is used, the allowable time between the introduction of the c ement to the aggregates and discharge of the concrete shall be increased to three hours. The limit of 300 maximum revolutions (pertaining to truck mixers or agitators) specified in AASHTO M 157 may be waived when hydration control stabilizing admixtures a re used, provided that no additional water is added prior to discharge of the concrete. A single batch of concrete containing a hydration control stabilizing admixture may not be discharged on more than one project. When a mix, containing a hydration control stabilizing admixture is used, and that mix has been approved for the three-hour discharge time, the reduced discharge time required when concrete temperatures are 85°F or above, and specified in the third paragra ph of this sub - section, shall not apply, provided that the concrete supplier has adjusted the hydration control stabilizing admixture dosage rate to account for that higher concrete temperature. The addition of water after completion of initial mixing wi ll not be permitted, except that when concrete is delivered in truck mixers, additional water may be added to adjust to a specified consistency. In this event, a minimum of 20 additional revolutions of the truck mixer drum at mixing speed shall be required before discharge of any concrete; the maximum allowable time between the addition of the cement to the aggregates and the discharge of the batch shall not be exceeded. Concrete that is not within the specified consistency limits at the time of placement shall not be used. When superplasticizer is used to adjust the consistency of a mix at the job site, as outlined in Section 601.3.2.1, water may still be used to adjust the consistency of the mix prior to the job site addition of superplasticizer, but no additional consistency adjustment of that mix with water shall be permitted after the job site addition of superplasticizer. The additional consistency testing required in Section 601.3.2.1 applies each time that superplasticizer is added at the job site. When superplasticizer is used to adjust the consistency of a mix at the batch plant, but not at the job site, as outlined in Section 601.3.2.1, additional consistency adjustment of that mix with water at the job site shall still be permitted. For all classes of concrete except Class H and concrete for specialized overlays, the total amount of water in a concrete mix, including any water added at the job site, shall not be more than the amount which would cause the water -cement ratio (w/c) of that concret e mix to exceed the w/c which corresponds to the Mix Design Approved Strength, as outlined in Section 5.4 of MP 711.03.23. The maximum water amount shall also be shown in Attachment 4 or 5 of MP 711.03.23 for all approved concrete mix designs. However, under no circumstances shall the w/c in Table 601.3.1A be exceeded. Shrink-mixed concrete is a ready-mixed concrete which is initially and partially mixed in a central mix plant and lastly mixed to completion in a truck mixer while in transit to or after arrival at the job site. Shrink -mixed concrete will be allowed for use in the work if specified in the Contract. 601.8-FORMS: 601.8.1-General: Forms shall be of wood, metal or other approved material and shall be mortar tight and sufficiently rigid to prevent distortion due to pressure of the concrete and other loads incidental to the construction operations including vibration. Wood forms shall be constructed and maintained so as to prevent the opening of joints due to shrinkage of the lumber. All falsework shall be designed and constructed to provide the necessary rigidity and to support the loads without appreciable settlement or deformation. Suitable jacks, wedges or other approved devices shall be used to maintain the forms at correct elevation and to permit lowering the centers gradually and uniformly without injury to the structure. Deck slab overhang forms shall be supported from the bottom flange of fascia girders or stringers. The Contractor shall s ubmit forming plans and supporting calculations for the overhang to the Engineer for approval prior to erecting the formwork. A "Telltale" or other approved type of indicator shall be attached to the forms and arranged in such a manner that any settlemen t or movement in the forms or falsework is indicated. Forms shall be filleted and chamfered as shown on the Plans and shall be given a bevel or draft in the case of all projections to assure easy removal. All field welding shall be performed by a certif ied welder. Welding of form ties and supports to the beam will not be permitted. Welding of screed rail supports will not be permitted in the top flange in tension zone. 601.8.2-Form Lumber: Form lumber for all exposed concrete surfaces shall be dres sed at least on one side and two edges. 601.8.3-Metal Ties: Metal ties or anchorages within the forms shall be constructed to permit their removal to a depth of at least one (1) inch from the face without injury to the concrete. Only rods shall be used for internal ties. The cavities shall be filled with cement mortar and the surface left sound, smooth, even, and uniform in color. 601.8.4-Cleanouts: Where the bottom of the form is inaccessible, the lower form area shall be left loose or other provisions made so that extraneous material may be removed from the forms immediately before placing the concrete. 601.8.5-Surface Treatment: Forms shall be treated with oil in such manner as to prevent contamination of reinforcing steel. Oil which will adhere to or discolor the concrete shall not be used. 601.8.6-Metal Forms: The metal used for the forms shall be of such thickness that the forms will remain true to shape. All bolts and rivet heads shall be countersunk. Clamps, pins, and other connecting devices shall be designed to hold the forms rigidly together and to allow removal without injury to the concrete. Metal forms which do not present a smooth surface or do not line up properly shall not be used. Metal forms shall be kept free of rust, grease, or other foreign matter. 601.8.7-Removal of Forms and Construction of Superimposed Elements: The forms for any portion of the structure shall n ot be removed until the concrete is strong enough to prevent damage. Methods of form removal likely to cause overstressing of the concrete shall not be used. The minimum requirements for removal of forms or supports and the construction of superimposed elements shall be as specified in Table 601.8.7. Due to continuity of reinforcement between placements and other issues, adjacent bridge deck placements shall be considered superimposed elements and must meet the minimum strength requirement in Table 601.8.7 before an adjacent placement in the sequence may be placed. In lieu of field cured cylinders for the determination of compressive strength required for from removal and construction of superimposed elements, the Contractor may use the Maturity Method for the estimation of concrete strength as outlined in MP 601.04.21. TABLE 601.8.7 Requirements for Removal of Forms and Construction of Superimposed Elements Structural Element Removal of Forms Placing Concrete In Superimposed Elements Compressive Strength-psi Compressive Strength-psi Bridge Decks 2000 3000 Columns 2000 2000 Walls & Beams 2000 2000 Footings 500 2000 Components Supported By Falsework 3000 3000 Parapets 2000 (See 601.11) ------------- 601.8.8-Slip Forming: Slip forming and related methods of placing concrete may be used. At the Contractor's option, parapet wall joints and median barrier on the bridge may be sawed in lieu of formed open joints and the joints shall be spaced as shown on the Plans and shall be 1/4 inch 1/16 inch wide. Joints shall be sawed full width from the top of the wall to the upper break point in the wall. From the upper break point to the bottom of the wall a two (2) inches minimum depth saw cut shall be made along the face and bac k of the wall. Joints shall be sealed in accordance with Section 501.16.1. The face of the back -up material shall be ½ inch minimum from the concrete surface. Initial sawing of joints shall commence as soon as the concrete has hardened sufficiently to permit sawing without excess raveling, usually 4 to 24 hours. All joints shall be initially sawed before uncontrolled shrinkage cracking takes place, but no later than 24 hours after placement of concrete. 601.8.9-Stay-in-Place Fabricated Metal Forms for Concrete Bridge Decks: All concrete bridge decks shall be constructed with a stay-in-place fabricated metal forming system per the requirements shown in this specification unless otherwise noted in the plans. 601.8.9.1-General: Stay-in-place fabricated metal forms for concrete deck slabs of bridges shall be used on all interior bays of beams. For overhangs and where longitudinal expansion joints are located between stringers removable forms shall be used. The design and material of the forms, in the judgment of the Engineer, shall be such as to give an expected maintenance free service life equal to the service life of the concrete slab. The stay- in-place fabricated metal forms shall be crimped at each end. Unless otherwise spe cified in the plans, the weight of stay -in-place fabricated metal forms plus concrete in the form flutes used in the design is 15 psf. The contractor shall submit revised computations if the proposed forming system is heavier than 15 psf. The cost of the revised computations shall be at no additional cost to the Division. 601.8.9.2-Material: Stay-in-place fabricated metal forms for concrete decks slabs and exposed material for supports shall be zinc -coated (galvanized) steel sheet conforming to ASTM A653, Designation SS, Grades 33 through 80, with a G165 Coating Designation. The stay-in-place fabricated metal forms shall be designed on the basis of dead load of the forms, reinforcement, and the plastic concrete plus 50 psf for construction loads. Unit working stresses shall be in accordance with the AASHTO LRFD Bridge Design Specifications for construction loads and the unit stress in the steel sheet shall be not more than 0.725 of the specified minimum yield strength of the material furnished but not to exceed 36,000 psi. Maximum deflection under weight of plastic concrete, reinforcement and form shall not exceed 1/180 of the form span or ½ inches, whichever is less. Maximum deflection under 60 psf of live loads shall not exceed 1/360 of the form spa n or ¼ inches, whichever is less. The form span for design and deflection shall be the clear distance between the flanges of the supporting beams less two (2) inches, measured parallel to the form flutes. All stay-in-place fabricated metal forms shall have a minimum thickness of 22 gage. Physical design properties shall be computed in accordance with requirements of American Iron and Steel Institute Specification for the Design of Cold -Formed Steel Structural members, latest published edition. All reinforcing bars in the bottom layer of the deck slab reinforcement shall have a minimum concrete cover of 1”. The distance from the top of the slab to the bottom layer of deck slab reinforcement shall not be less than that shown on the plans. 601.8.9.3-Installation: All forms shall be installed in accordance with detailed fabrication plans submitted to the Engineer for approval. The fabrication plans shall clearly indicate locations where the forms are supported by steel beam flanges. Form sheets shall not be permitted to rest directly on the top of the stringer or floor beam flanges. Sheets shall be securely fastened to form supports and shall have a minimum bearing length of 1” at each end. Form supports shall be placed in direct contact with the flange of stringer or floor beam. All attachments shall be made by bolts, clips, or other approved means. Welding of form supports to flanges shall not be permitted. Any exposed form metal where the galvanized coating has been damaged shall be thoroughly cleaned and wire brushed, and then painted with two coats of zinc-rich primer, conforming to Subsection 711.21, to the satisfaction of the Engineer. Transverse construction joints shall be located at the bottom of a flute and ¼” weep holes shall be provided in the field at 12” 3” on center along the line of the joint. 601.8.9.4-Placement of Concrete: Concrete shall be placed in accordance with the contract specifications. The entire form shall be filled with deck concrete. No filler material shall be permitted. Particular emphasis should be placed on proper vibration of the concrete to avoid honeycomb and voids, especially at construction joints, expansion joints, flutes, and ends of form sheets. The use of covered flutes or fillers of any kind in the flutes of the stay-in-place fabricated metal forms is not permitted. Prior to placement of concrete, the Contractor shall submit to the Engineer for approval Concrete Volume to Stay in Place Form Adjustment Factor ( SIPadj). The SIPadj shall be the equivalent ratio of the concrete volume in the form flutes to Square Yard of Stay -In- Place Form Area. 601.8.9.5-Inspection: The Contractor's method of construction shall be carefully observed during all phases of the construction of the bridge deck. These methods include installation of the Stay -in-place fabricated metal forms; location and fastening of the reinforcement; composition of concrete, placement and vibration; and finishing of the bridge deck. Unless waived by the Engineer, the Contractor shall remove at least one section of the forms at a location and time selected by the Engineer for each concrete placement in each approved pour sequence. This should be done as soon after placing the concrete as practicable in order to provide visual evidence that the concrete mix and the Contractor’s procedures are obtaining the desired results. An additional section shall be removed each time the concrete mix or the contractor’s procedures are changed, unless waived by the Engineer. After the deck concrete has been in place for a minimum of two days, the concrete shall be tested for soundness and bonding of the forms by sounding on the forms with a hammer at least 50 percent (50%) of the area of at least 25 percent (25%) of the individual f orm panels, as selected by the Engineer on a random basis. If areas of doubtful soundness are disclosed by this procedure, the Contractor will be required to remove the forms from such areas for visual inspection. At locations where sections of the forms are removed, the Contractor will not be required to replace the forms, but the adjacent metal forms and supports shall be repaired to present a neat appearance and assure their satisfactory retention. As soon as the form is removed, the concrete surfaces will be examined for cavities, honeycombing and other defects. If irregularities are found, and in the opinion of the Engineer these irregularities do not justify rejection of the work, the concrete shall be given a Class 1, Ordinary Surface Finish in accordance with the contract specifications and shall be repaired as the Engineer may direct. If the concrete where the form is removed is unsatisfactory, additional forms shall be removed, as necessary, to inspect and repair the slab, and the Contractor's methods of construction shall be modified as required to obtain satisfactory concrete in the slabs. The amount of sounding and form removal may be moderated, at the Engineer's discretion, after a substantial amount of slab has been constructed and inspect ed if the Contractor's methods of construction and the results of the inspections as outlined above indicate that sound concrete is being obtained throughout the slabs. The Contractor shall provide all facilities required for the safe and convenient conduct of the Engineer's inspection procedures. 601.8.9.6-Forming System Changes: The contractor shall not utilize a removable forming system without the submittal of the following information:
1.Revised camber tables based on actual forming system.
2.Revised dead load deflection tables based on actual forming system. These revised drawings must be stamped by a West Virginia Professional Engineer and approved by the Engineer prior to commencing forming. No change in unit prices, or contract completion date will be permitted for the use of a removable forming system. 601.8.10-Architectural Formwork: 601.8.10.1-General: This work includes additional requirements for the forming of cast-in-place structural concrete designated as architectural. The s cope of this work is as indicated and as detailed on the drawings. 601.8.10.2-Submittals: The following shall be submitted to the Engineer for his review:
A.Product data and installation instructions for manufactured form systems, form liners, release agents, ties, and accessories. The release agent manufacturer shall certify that the products supplied comply with regulations controlling the use of volatile organic compounds (VOC's).
B.Shop drawings for fabrication and erection. These drawings shall show all items that visually affect the exposed concrete, including, but not limited to, general form construction, jointing, specially formed joints or reveals, and patterns of placement. The Engineer’s review will be for general architectural applicat ions and features only. Formwork design for structural stability and sufficiency is the Contractor's responsibility and shall not be submitted for the Engineer’s review.
C.Mockup or Sample Panels. The Contractor shall submit a mockup or sample panel of their respective material indicating texture, finish, and pattern in accordance with Section 601.8.10.3.A. This Mockup or Sample Panel shall have a minimum front surface area of 15 ft2. 601.8.10.3-Quality Assurance:
A.The Contractor shall construct a mockup or sample panel using the proposed formwork and facing materials in order to demonstrate the required finishes and textures. Actual construction of architectural concrete shall not proceed until the Engineer has accepted the sample units.
B.Before placing conc rete, the Contractor shall check lines and levels of erected formwork, and shall make corrections and adjustments to ensure:
1.proper size and location of concrete members
2.stability of the forming systems
C.During concrete placement, the Contractor shall chec k formwork and related supports to ensure the forms are not displaced and that completed work will be within specified tolerances. 601.8.10.4-Materials: 601.8.10.4.1-Form Materials:
A.Forms for Exposed -Finish Concrete: Unless otherwise indicated, construct formwork for exposed concrete surfaces with plywood, metal, metal -framed plywood-faced or other paneled materials to provide as-cast surfaces. Furnish in largest sizes to minimize number of joints and to conform to joint system shown on drawings. Provide form materials with sufficient thickness to withstand pressure of placed concrete without bow or deflection beyond allowable tolerances.
1.Use overlaid plywood, APA grade trademarked "High Density Overlay (HDO)."
2.Use plywood, APA grade trademarked "B-B Plyform Class 1."
B.Forms for Textured Finish Concrete: Provide special forming materials to produce surfaces with face design, texture, arrangement, and configuration as shown on drawings or as required to match Engineer's control sample. Provide solid backing and form supports to ensure stable textured form liners.
C.Form Coating: Provide a commercial formula release agent that will not bond with, stain, or adversely affect concrete. Provide material that will not impair subsequent treatment of concrete surfaces requiring bond or adhesion, nor impede wetting surfaces to be cured with water or a curing compound. 601.8.10.4.2-Formwork Design: Design formwork for easy removal without impact, shock, or damage to the concrete and adjacent materials. 601.8.10.5-Construction Methods: 601.8.10.5.1-Form Construction:
A.General: Construct forms to sizes, shapes, lines, and dimensions shown, and as required to obtain accurate alignment, location, level, and plumb work in finished structures. Pro vide for openings, offsets, keyways, recesses, chamfers, blocking, screeds, bulkheads, and other as required.
B.Fabricate forms to prevent cement paste from leaking while placing concrete and for easy removal without hammering or prying against exposed concrete surfaces. Provide crush plates where stripping might damage cast concrete surfaces. Provide top forms for inclined surfaces where slope is too steep to place concrete. Solidly butt joints and provide backup material at joints to prevent leakage and fins. Assemble forms so that they may be easily removed without damaging exposed concrete surfaces
C.Provide temporary form openings where inaccessible formwork interior can be cleaned and inspected before placing concrete. Place temporary form openings as inconspicuously as possible, consistent with project requirements.
D.When drilling forms used for exposed concrete, drill from the contact face to the outside to suit the ties used and to prevent leakage of concrete mortar. Do not splinter the forms by driving ties through improperly prepared holes.
E.Unless otherwise shown in the plans,
1.provide sharp, clean corners at intersecting planes with no visible edges or offsets.
2.provide accurately formed chamfered corners using ¾ x ¾ inch strips, surfaced to produce uniformly straight lines and tight edge joints. 601.8.10.5.2-Form Coatings:
A.General: Coat form contact surfaces with form -release agent before placing reinforcement. Do not allow excess material to accumulate in forms or to come into contact wi th reinforcement or surfaces that will be bonded to fresh concrete. Apply coating according to manufacturer's instructions.
B.Coat steel forms with non -staining, rust -preventative release agent, or otherwise protect from rusting. Rust -stained steel formwork is not acceptable. 601.8.10.5.3-Reusing Forms: Split, frayed, delaminated, or otherwise damaged form-facing materials are not acceptable. Clean and apply a new form -release agent to concrete contact surfaces. 601.9-ADVERSE WEATHER CONDITIONS: 601.9.1-Cold Weather Concreting: The plastic concrete shall have a temperature of at least 50F but not more than 85 F at the time of placing. When the plastic concrete has a temperature of less than 55 F, the provisions for cold weather concreting shall apply. Maintenance of at least the minimum temperature shall be accomplished by heating the water or the aggregates, or both, as necessary. Heating methods which alter or prevent the entrainment of the required amount of air in the concrete shall not be used. Heating equipment shall be capable of heating the materials to achieve the specified temperature of the plastic concrete. The temperature of the aggregates or water shall not exceed 150 F at the time the cement is added to the mixture. Materials containing frost or l umps of frozen materials shall not be used. If the Contractor is placing concrete or plans to place concrete during cold weather conditions, the Contractor shall advise the D ivision of his plans for curing and protecting the concrete. The Division may at any time, require the Contractor to provide additional protection to cause the provisions of this specification to be met. Stockpiled aggregate may be heated by the use of dry heat or steam. Aggregates shall not be heated directly by gas or oil flame or on sheet metal over fire. Binned aggregates may be heated by steam -coil or water -coil heating. The use of live steam on or through binned aggregate will not be permitted. The use of calcium chloride to hasten the initial set of structural concrete will not be permitted. Insulated forms may be used for protecting and curing concrete. There will be no additional cost to the Division for the use of insulated forms. Class H or Class K Concrete Cold Weather Provisions: Cold weather periods shall be defined as those periods when temperatures above 50° F do not occur for more than half of any 24 hour duration. The temperature of the surface on which the concrete is to be placed shall not be less than 45° F immediately prior to placement of the concrete. During the cold weather periods, as defined above, the temperature of the concrete immediately after placement shall be between 55 and 75°F. 601.9.2-Hot Weather Concreti ng: The Contractor will be required to state, at the pre - construction conference, his plan of action when the temperature of plastic concrete reaches 90F. When a free air, shaded thermometer in the vicinity of the concrete production plant reaches 85F, thermometer readings of the temperature of the plastic concrete shall be taken at least hourly. When the temperature of the plastic concrete reaches 85 F, the elapsed time between the introduction of the mixing water to the cement -aggregates and discharge of the mix shall not exceed 1 hour. At this temperature or above, particula r attention shall be paid to the Specification provisions concerning the sprinkling and wetting of surfaces not oil -treated, the maintenance of coarse aggregate stock in saturated surface-dry condition, and the prompt start of concrete curing operations. When the temperature of the plastic concrete reaches 90F, immediate steps shall be taken to cool either mixing water or aggregates, or both, in order to maintain a plastic co ncrete temperature of 90F or less. Crushed or flaked ice may be used to cool t he mixing water. Crushed or flaked ice may also be introduced into the mixing drum when the concrete is batched and mixed in a truck mixer. The ice will be considered as part of the mix water in the mix proportions. The mixing operation shall not be considered complete until all ice in the drum has melted. In no event shall concrete be placed when its temperature in the plastic state at the completion of mixing exceeds 90F. Bridge Decks: The Contractor's plan of action for all bridge deck concreting operations shall contain provisions designed to minimize the probability that any bridge deck concrete will be placed when the ambient temperature is greater than 85F.
601.10 Placing Concrete:
601.10.1 General: Concrete shall not be placed until forms and reinforcing steel have
been inspected and approved. The forms shall be cleaned of all debris immediately prior to placing concrete, and surfaces not oil treated shall be wetted. The method and sequence of placing concrete will be subject to approval by the Engineer. Concrete shall be placed so that no segregation will occur and no displacement of reinforcement will be caused. Concrete shall be placed in the forms as nearly as practical in its final position in order to avoid rehandling, and an approximately horizontal surface of the plastic concrete shall be maintained. After initial set of the concrete, the forms shall not be jarred and no strain shall be placed on the ends of projecting reinforcement. Co ncrete shall not be placed until all laitance which may have formed on concrete previously placed, or any loose deleterious material on reinforcing bars, has been removed.
601.10.1 1-Pre-Pour Meeting: On projects for which the concrete is being used in
bridge construction, the Contractor shall schedule a meeting prior to the start of the concrete work. The Engineer, Construction Manager, Prime Contractor, Concrete Contractor, Concrete Finisher, Concrete Supplier, and the Individual or Agency that wil l perform the quality control testing of the concrete shall attend. Topics of discussion shall include concrete mixture proportions, batching, transporting, handling, placing, finishing, curing, and on-site quality control testing requirements.
601.10.1 2-Concrete Placement Limitations: Immediately prior to, and during,
placement of Class H concrete, if the evaporation rate exceeds 0.10 lb./sq. ft. per hour (see Figure 1), the Contractor shall make provisions (i.e. wind breaks, fogging, etc.) to reduce the rate prior to placing concrete. These provisions shall be maintained during the placement of the concrete. If the evaporation rate obtained from Figure 1 is close enough to the maximum allowable value of 0.10 lb./sq. ft. per hour that there may a discrepancy in the exact numerical value, the following equation shall be used to obtain a more accurate value. E = [Tc2.5 – (r x Ta2.5)] [1 + 0.4V] x 10-6 Where: E = evaporation rate, lb/ft2/h Tc = concrete temperature, °F Ta = air temperature, °F r = (relative humidity %) / 100 V = wind velocity, mph Example: Air Temperature = 65 °F Relative Humidity = 45% Concrete = 60 °F Temperature Wind Velocity = 20 mph Result Using Figure 1: Evaporation Rate ≈ 0.11 lb/ ft2/h Result Using Formula: E = [Tc2.5 – (r x Ta2.5)] [1 + 0.4V] x 10 -6 E = [602.5 – (0.45 x 652.5)] [1 + (0.4 x 20)] x 10 -6 E = [27885 – 15328] [1 + 8] x 10 -6 E = 12557 x 9 x 10 -6 E = 0.11 lb/ ft2/h
601.10.1 3-ConcretePlacementatNight:If placement of any concrete is to be made at night,
a plan which provides adequate lighting for the work area shall be submitted at least 14 days before concrete is placed for the Engineer's approval.
601.10.2 Chutes and Troughs: Concrete shall not be dropped in the forms a greater
distance than five (5) feet without the use of closed chutes or pipes. When chutes or troughs are used under steep slope conditions, they shall be equipped with baffle boards or sh all be used in short lengths to reverse the direction of movement. All chutes, troughs or pipes shall be kept clean and free of hardened concrete by flushing with water after each run. Flushing water shall be discharged outside the forms. Aluminum chute s, troughs or pipes shall not be used.
601.10.3 Vibrating: Concrete shall be compacted by the operation of approved
mechanical vibrators within the concrete. When required, vibrating shall be supplemented by hand spading to assure proper compaction, to force all coarse aggregate from the surface, and to bring mortar against the forms to produce a smooth finish. Vibrators shall be manipulated in such a manner that concrete is worked around reinforcement and imbedded features and into angles of the form. Vibration shall be of sufficient duration to accomplish co mpaction but shall not be prolonged to the point where segregation occurs. Vibration shall not be used to cause concrete to flow from point to point within forms. The frequency of the vibrators shall meet the requirements of Section 501.5.5.
601.10.4 Placing Concrete Bridge Decks: Concrete for bridge decks shall be placed and
finished with mechanical equipment, as outlined in Section 601.5.5, unless waived by the Engineer. The Contractor shall furnish the Engineer information as to the weight of the proposed machine, the volume of concrete to be placed per hour, and the operating procedure to be followed. Where beam support screeds are used and the distance between the support and gutter line is in excess of one (1) foot, the Contractor shall use devices to control the grade of the gutter line during the deck finishing operations.
601.10.4 1-Fogging Equipment: When Class H concrete is used, fogging equipment shall
be available for use in accordance with these specifications. The fogging nozzles shall produce an atomized mist. Fogging nozzles shall incorporate compressed air to create the mist. Hand held or hand operated equipment shall be permitted when the Contractor has demonstrated that his operator has been trained in its use.
601.10.4 2-Placement: The following requirements shall apply during placement of the
Bridge Deck concrete:
a.So that the use of hand tools will be kept to a minimum, concrete shall be deposited as nearly as possible to its final position. Internal vibrators shall not be used for moving concrete into position.
b.A pencil type vibrator shall be used along all construction joints to further consolidate the concrete to prevent voids.
c.The new concrete shall be placed slightly above final grade. It shall then be struck-off, screeded, and finished to final grade.
d.The finished surface, before texturing, shall be uniformly smooth, dense and even. Variations in pavement surface in excess of 1/8 inch above, or below, the proper finished elevation, or surface irregularities of more than 1/8 inch in ten (10) feet, will not be accepted.
e.A construction dam, or bulkhead, shall be installed in case of a delay in the placement operations exceeding 30 minutes duration. During any delays of 30 minutes or less, the placement shall be protected from drying with several layers of wet burlap. If the concrete placement is stopped, or delayed, for 90 minutes or more, further placement shall be discontinued and may be resumed only after the concrete has cured. This restriction does not prohibit continuation of the placement provided a gap is left in the placement. This gap shall be sufficient in length to allow the finishing machine to clear the previously placed concrete.
f.Adequate precautions shall be taken to protect freshly placed concrete from rainfall. All placement operations shall stop when it starts to rain. The Engineer may order removal and replacement of material damaged by rainfall.
g.The addition of superficial water to the surface of the concrete to assist in finishing operations will not be permitted.
601.10.5 Depositing Concrete Under Water: Concrete shall not be placed until all
laitance which may have formed on concrete previously placed has been removed. Still water shall be maintained at the point of deposit. While depositing foundation concrete, pumping shall be discontinued if it res ults in a flow of water inside the forms. All concrete deposited under water shall have the minimum cement content increased at least 10 percent (10%). Concrete deposited under water shall be carefully placed in a compact mass in its final position by means of a tremie, a closed bottom dump bucket, or other approved method and shall not be disturbed after being deposited.
601.11 Finishing Concrete Surfaces:
The surface of the concrete shall be finished immediately after form removal. The exposed surfaces of bridge parapets, wingwalls, headwalls and vertical edge of the bridge deck shall be given a Class 2, Rubbed Finish, or a Class 1, Ordinary Surface Finish supplemented with wood float rubbing. When the Class 1, Ordinary Finish is used, the forms shall be removed as early as practical, not to exceed six hours (in lieu of 601.8.7) after placing, and the finish completed including rubbing with a wood float and water. The rubbing shall produce a nonplastered, smooth textured and uniform color surface. Other concrete surfaces except bridge decks shall be given a Class 1, Ordinary Finish. Unless otherwise shown in the plans, all concrete designated as architectural shall receive a Class 1, Ordinary Surface Finish, as defined in Section 601.11.1.
601.11.1 Class 1, Ordinary Surface Finish: Immediately following the removal of the
forms, all fins and irregular projections shall be removed from all surfaces except those which are not to be exposed or are not to be waterproofed. On all surfaces the cavities produced by form ties and all other holes, honeycomb spots, broken corners or edges and other defects shall be thoroughly cleaned, saturated with water, and carefully pointed and trued with a mortar of cement and fine aggregate mixed in the proportions used in the class of concrete being finished. Mortar used in pointing shall be not more than 30 mi nutes old. The mortar patches shall be cured as specified in 601.12. All construction and expansion joints in the completed work shall be left carefully tooled and free of all mortar and concrete. The joint filler shall be left exposed for its full length with clean and true edges. The resulting surfaces shall be true and uniform. All surfaces which cannot be repaired to the satisfaction of the Engineer shall be rubbed as specified for Class 2, Rubbed Finish.
601.11.2 Class 2, Rubbed Finish: After removal of forms, the rubbing shall be started as
soon as the condition of the concrete will permit. The concrete shall be thoroughly saturated with water immediately prior to rubbing and shall be kept saturated throughout the rubbing operation. Sufficient time shall have elapsed before wetting down to allow the mortar used in pointing to thoroughly set. Surfaces to be finished shall be rubbed with a medium coarse carborundum stone, using a small amount of mortar on its face. The mortar shall be compo sed of cement and fine sand in the same proportion as the concrete being finished. Rubbing shall be continued until all form marks, projections, and irregularities have been removed, all voids filled, and a uniform surface obtained. The past produced by this rubbing shall be left in place. After all concrete above the surface being treated has been cast, the final finish shall be obtained by rubbing with a fine carborundum stone and water. This rubbing shall be continued until all the paste produced by the first rubbing operation has been removed from the face of the concrete except from depressions and defects which have been filled with the paste. The surface of the concrete after rubbing shall have a non-plastered, smooth texture and a uniform color. After the final rubbing is completed and the surface has dried, the surface shall be rubbed with burlap to remove loose powder. The resulting surfaces shall be free from all unsound patches, paste, powder, and objectional marks.
601.11.3 Class 6, Float Finish: This finish, for horizontal surfaces, shall be achieved by
placing an excess of material in the form and removing or striking off the excess with a template, forcing the coarse aggregate below the mortar. Creation of concave surfaces shall be avoided. After the concrete has been struck off, the surface shall be thoroughly worked and floated with a suitable floating tool of wood, canvas or cork. Before the finish has set, the surface cement film shall be removed with a fine brush in order to have a fine grained, smooth but sanded texture.
601.11.4 Finishing Concrete Bridge Decks: Any addition of water to the surface of the
concrete to assist in the finishing operations will not be permitted. When conditions are such that unusually rapid drying is occurring, an atomized mist may be used to prevent the rapid evaporation of water from the concrete surface during the final finishing.
601.11.4 1-Class K Bridge Decks: After striking off, consolidating, and floating have
been completed, both while the concrete is still plastic, the surface shall be checked for trueness with a straightedge. The Contractor shall furnish an accurate scraping type straightedge with a minimum length of ten ( 10) feet and swung from a handle at least three (3) feet longer than one-half the width of the slab. The straightedge shall be held in successive positions parallel to the road centerline and in contact with the roadway surface and operated from side to side until the surface is within the permi ssible tolerance provided. Advance along the roadway shall be in successive stages of not more than one -half of the length of the straightedge. Any depressions found shall be immediately filled with freshly mixed concrete, struck -off, consolidated, and refloated. High areas shall be cut down and refloated. The straightedge testing and reflecting shall continue until the surface is found to be free from observable departures from the straightedge and the slab has the required grade and contour. Upon completion of the above operations, the surface shall be smoothed with a lute or smoothing float, four (4) to six (6) feet in length, after which the surfaces shall be tested with an accurate straightedge. This checking straightedge shall be ten (10) feet long and shall be held in a position parallel to the centerline of the roadway. The advance of this straightedge along the slab shall be in successive stages of not more than one -half of its length. When tested with this straightedge, the finished surface shall be free from observable departures from the straightedge. Upon completion of the above operations, the surf ace of the concrete shall be given a groove finish while the concrete is still plastic. The tool used shall produce a groove that is approximately 3/32 inch wide. The depth of this groove shall be 1/8 inch to 3/16 inch and spaced approximately ½ inch cen ter to center. The grooves shall be formed in a direction that is transverse to the centerline of the roadway or parallel to the skew. On any one bridge the direction of the grooves shall be consistent. Adjacent strokes to establish the texture shall ab ut one another without appreciable overlap. Texturing shall be performed when the concrete surface is of such plasticity as to prevent excessive raveling (concrete too dry) or to prevent mortar from flowing back into the grooves (concrete too wet). All t exturing shall be accomplished with a single pass of the tool. To facilitate drainage, the twelve ( 12) inches immediately adjacent to the curbline shall be left untextured. Instead of forming the grooves into the plastic concrete by tining, as specified in the previous paragraph, the Contractor may sawcut the grooves into the hardened concrete bridge deck as specified in Section 601.11.4.4. All sawcutting shall be performed before any sealing operations required in Section 601.13.1. No additional paymen t will be made for constructing this type of bridge deck surface.
601.11.4 2-Class H Bridge Decks: The surface of the Class H concrete shall be
uniformly smooth, dense and even. The surface shall then be given a suitable texture with an approved burlap drag. The Contractor shall texture in a transverse or longitudinal direction. Once begun, the direction of texturing shall not change. All texturing shall be performed prior to the beginning of curing operations. Only one pass of the drag over the f inished area will be permitted. Texturing shall be in strict accordance with the time requirements of subsection
601.12.4 for applying wet burlap.
If texturing is done in the transverse direction, the Contractor shall texture by hand methods as soon as p racticable after finishing machine passage, without any additional finishing operations between the machine passage and texturing operations. If texturing is done in the longitudinal direction, the burlap drag shall be a seamless strip and shall be attach ed to the work bridge such that the surface of the concrete is textured as soon as practicable after finishing machine passage, without any additional finishing operations between the machine passage and texturing operations. Small areas, inaccessible to the attached drag, may be textured by hand methods. The finishing movement and resulting progress of the burlap drag shall be done in a manner so as to prevent ridges or gouges from forming in the concrete surface. The drag shall be weighted and the contact area changed as required to produce a texture acceptable to the Engineer. The drag shall be cleaned as required; to remove all hardened concrete particles and shall be replaced after each day’s operation. Texture resulting from the drag shall stop within one foot of curbs or parapets. Any hand finishing operations shall be kept to a minimum for Class H bridge decks.
601.11.4 3-Straightedge Testing of Hardened Bridge Decks: When finishing has
been completed and the concrete has hardened sufficient ly, the surface shall be given a further test for trueness with a rolling straightedge or a certified inertial profiler and operator (see Section 720.2.). When using a rolling straight edge, areas showing high spots of more than ⅛ inch shall be marked by the Engineer. When an inertial profiler is used, the data shall be analyzed by using the rolling straight edge simulation on the most recent version of ProVal Software. Areas showing more than ⅛ inch on the rolling straight edge simulation will be mapped showing locations. Only when directed by the Engineer, such areas that are higher than ⅛ inch shall be ground with an approved grinding tool, utilizing carborundum stones or industrial diamond wheels; grinding shall be done to an elevation where the area or spot will not show a surface deviation in excess of ⅛ inch when tested with the ten (10) feet rolling straightedge, except that the maximum depth of grinding shall not exceed ¼ inch. The ground areas shall be treated as directed by the En gineer. Where the initial deviation from the straightedge is ½ inch or more, the Contractor will be required to remove and replace the complete pour in which the areas not meeting the required tolerance are located. After grinding, all areas either high or low, not meeting the requirements of ⅛ inch tolerance will be measured and disposition of these areas will be as set forth in subsection
601.15 2.
601.11.4 4-Class H Concrete Finished Deck Grooving: After completion of water
curing the concrete and after corrective grinding, but before opening the bridge to traffic, saw longitudinal or transverse grooves in accordance with the following applicable subsection.
601.11.4 4.1-Transverse Grooving: After corrective grinding and before opening to
traffic, grooves shall be cut into the concrete using a mechanical saw. These grooves shall be 0.10 inch wide and 0.25 inch deep. Groove spacing shall be 1.5 inches center to center. No later than one week pr ior to grooving operations, the Contractor shall provide the Engineer with two accurate, easily readable gauges with which to verify groove dimensions. Groove depth and spacing tolerances are limited to ±1/16 inch. Groove width tolerances are +0.02 inch an d -0.0 inch. The grooves shall be cut in a direction that is transverse to the centerline of the roadway or parallel to the skew. On any one bridge the direction of the grooves shall be consistent. Grooves shall be cut continuously across the deck to withi n one foot of gutter lines or drainage structures. Grooves shall also be continuous across the full width of the deck surface including construction joints. Grooves shall terminate within one ( 1) inch of any exposed metal component or elastomeric concrete of an expansion joint. When the deck is skewed and the contractor is using gang blades to saw the grooves, the maximum distance (measured perpendicular to the centerline of the expansion joint) from the last groove termination in the pass to the expansion joint shall be one (1) foot – eight (8) inches. Radial grooving shall be performed in increments limited to twelve (12) feet of bridge length.
601.11.4 4.2-Longitudinal Grooving: Use diamond blades mounted on a multi -blade
arbor on self-propelled machines that were built for grooving of concrete surfaces. The groove machines shall have depth control devices that detect variations in the pavement surface and adjust the cutting head height to maintain the specified depth of the groove. The grooving machines shall have devices to control alignment. Do not use flailing or impact type grooving equipment. More than one size grooving machine may be required in order to saw the grooves as specified. Provide an experienced technician to super vise the location, alignment, layout, dimension, and grooving of the surface. Saw grooves parallel to the bridge centerline in a continuous pattern across the surface. Begin and end sawing nine (9) to twelve (12) inches from any device in place in a brid ge deck, such as scuppers or expansion joints. Stop sawing a minimum of two (2) inches to a maximum of twenty-four (24) inches from skewed expansion joints. Maintain a clearance of a minimum of 2 inches and a maximum of four ( 4) inches from the grooves to longitudinal joints in the deck. Maintain a minimum clearance of nine ( 9) inches to a maximum of thirty (30) inches clearance between the grooves and the curb or parapet toe. However, at no point shall un-grooved portions of deck extend beyond edge line an d into the temporary or permanent travelled lanes. Saw grooves in a uniform pattern spaced at 3/4 inch minus 1/4 inch or plus zero (0) inches. Saw grooves 0.15 inches deep and 0.10 inches wide. Groove tolerances for depth are +0.0625 inches and minus zero (0) inches. Groove tolerances for width are +0.02 inches and minus zero (0) inches. For staged, or phased bridge deck work, saw the grooves parallel to the final, permanent bridge centerline. If the different stages or phases of the bridge deck work occur within one construction season, any stage opened to traffic shall receive an interim coarse broom finish during placement, then saw the longitudinal grooves after the final stage. The interim broom finish will not be allowed as a surface texture when opened to traffic over a winter season. Saw longitudinal grooves in the deck prior to opening to traffic for a winter season. For bridge decks that widen from one end to the other, saw the longitudinal grooves parallel to the centerline of the roadway. On the side of the bridge that widens, saw the longitudinal grooves to follow the edge line. Saw longitudinal grooves in the gore areas, avoiding the overlapping of grooves. At the beginning of each work shift, furnish a full complement of grooving blades with each saw that are capable of cutting grooves of the specified width, depth, and spacing. If during the work, a single grooving blade on a machine becomes incapable of cutting a groove, continue work for the remainder of the work shift. The Contractor is not required to cut the groove omitted because of the failed blade. Should two or more grooving blades on a machine become incapable of cutting grooves, cease operating the machine until it is repaired. Continuously remove all slurry and remaining residue from the grooving operation and leave the deck surface in a clean condition. Prevent residue from grooving operations from flowing across shoulders or across lanes occupied by public traffic or from flowing into gutters or other drainage facilities. R emove solid residue before the residue is blown by passing traffic or by wind. Provide water as necessary to saw grooves according to this subsection.
601.12 Curing and Protecting Concrete:
601.12.1 Curing Under Normal Conditions: All concrete shall be protected by one or
more of the curing materials, meeting the requirements of Subsection 601.2, as soon as possible after placement to prevent loss of moisture from the surface. Burlap and water curing shall be used on all bridge decks. The temperature of the curing water shall not exceed the maximum ambient temperature of the last 24 hours by more than 5°F. Concrete surfaces shall be kept completely and continuously moist. Curing shall be continued for a period of at least 7 days. This curing period may be reduced if the contractor presents evidence that the in-place concrete has attained 70% of the specified strength for the class of concrete under cure. Under no circumstances, shall the period of cure be less than 3 days. The reduced curing period option is not applicable to Class H or Class K concrete. When placing concrete elements with a minimum dimension greater than two (2) feet, the contractor shall not be permitted to add additional cement to the target cement factor in the approved mix design in order to obtain high -early strength and/or reduce curing time. Surfaces may have coverings temporally removed for finishing, but the covering shall be restored as soon as possible. Membrane forming curing compounds may be used providing they do not conflict with other requirements of these Specifications. If membrane forming curing compou nd is used, all surfaces shall be given the required finish prior to application of the curing compound with the concrete protected by some other method before finishing. Curing compound shall be applied at a minimum rate of one gallon of liquid coating per 300 square feet of concrete surface for each application. The curing compound shall be continuously agitated during use. All concrete cured by this method shall receive two applications of the curing compound. The first coat shall be applied immediately after acceptance of the concrete finish. If the surface is dry, the concrete shall be saturated with water and the curing compound applied as soon as the surface film of water disappears. The second application shall be made after the first application has set. Placement in more than two coats may be required to prevent streaking. During the curing period, any coating marred or otherwise disturbed shall be given an additional coating. Should the surface coating be subjected continuously t o injury, another method of cure shall be immediately substituted. If the use of an impervious compound results in a streaky or blotched appearance, the method shall be stopped and water curing applied until the cause of the defective appearance is corrected. Curing Temperature is the air temperature at the concrete surface, or the air temperature between the concrete surface and its protective covering.
601.12.2 Curing Under Cold Weather Conditions: When the air temperature is
expected to fall below 30F, the Contractor shall provide suitable measures to maintain the concrete surface temperature between 50F and 90F. Calendar days on which the surface temperature of the concrete falls below 50F shall not be considered days of curing. In no event shall the temperature of the concrete be allowed to fall below 35F before the specified curing is completed. The Contractor shall be responsible for the quality and strengths of the concrete placed or cured, or both, during the cold weather, and any con crete injured by frost action shall be removed and replaced at the Contractor's expense. When protection is removed from the structure after the specified curing is complete, the temperature of the concrete shall not be permitted to fall at a greater rate than 20F per 24 hour period. Class H or Class K Concrete Provisions: The surface temperature of the concrete shall be maintained between 55 and 75°F for 72 continuous curing hours immediately after placement. After this 72 hour period, a minimum concrete surface temperature of at least 50°F shall be maintained for an additional 96 continuous curing hours. If it is expected that the surface temperature of the concrete will drop below 50°F during the 168 hour curing period, then the surfac e shall be enclosed and external heat shall be provided in accordance with the provisions of this section. Once external heat provisions are required, they shall remain on the surface until curing is complete, regardless of the ambient air temperature. Enclosures for heat retention shall be properly vented to prevent surface disintegration from carbon dioxide gas. Continuous wetting shall be replaced by wetting at regular intervals if, in the opinion of the Engineer, expected air temperatures could result in freezing of run-off water.
601.12.3 Protection of Finished Surfaces: All exposed finished surfaces of concrete shall
be protected to prevent rust stains, paint splotches, scars or other blemishes tending to disfigure or discolor the finished surfac e. Where reinforcing steel bars or other steel inserts are left exposed for extended periods or over the winter, they shall be given a coat of neat cement paste to prevent rust staining. Water runoff from concrete curing operations shall be deflected away from the steel girders and shall not drain onto the substructure concrete after contacting the weathering steel. Any stains or other blemishes shall be corrected by the Contractor.
601.12.4 Curing Class H Concrete: It is the nature of Class H concrete material to quickly
form a plastic film at the surface upon drying. This film is to be protected from drying and cracking by prompt covering with wet burlap. Regardless of the type of concrete placed, the use of membrane curing compounds will not be allowed. Floor drains shall be immediately unplugged to permit the deck to drain. The concrete surface shall be completely covered with clean, wet burlap. The burlap shall be thoroughly saturated over its entire area, but shall be drained of excess water before application. Burlap shall be lapped a minimum of one foot and shall lay flat. Failure to apply wet burlap within 30 minutes after discharge of the concrete from the truck and within 10 minutes of the completion of finishing operations shall be cause for rejection of the work as determined by the Engineer. Care shall be exercised to ensure that the burlap is well drained. Burlap shall be continuously wet for a period of seven days by means of automatic intermittent sprinkling or a continuous wetting system.
601.12.5 Protecting Concrete Decks: Construction equipment with an axle load greater than
20,000 lbs shall not be permitted on bridge deck. Construction equipment or loads that are not required to complete the slab, parapets, railing overlay, or other appurtenances shall not be allowed on the bridge deck.
601.13 Protective Surface Treatment:
601.13.1 Silane Treatment for Bridge Superstructure: After the concrete has achieved
a minimum of 80% of the design strength, a silane protective treatment as specified shall be applied to the entire top surface of bridge decks, approach slabs when they are included in the Contract, concrete bridge medians, top and curb face of bridge sidewalks, and the inside faces of parapets. When approach slabs are specified to be overlayed with asphalt, the sila ne treatment is not required. The application of this silane protective surface treatment is not required for elements constructed from Class H concrete. The surface to receive the treatment shall be dry for at least 48 hours before treatment and shall be free from sand, surface dust and dirt, oil, grease, chemical films, and other contaminants prior to application of the silane. Immediately before application, the entire surface shall be air blown to remove any loose dust. The surface, air, and material temperatures shall be between 40 and 100° F during application, and temperatures above 40° F, without precipitation, must be forecast for the twelve hours following application. Any coating damaged by rain or moisture shall be corrected by an additional application. The surface treatment shall consist of one of the silane sealers listed on the Division’s Approved Product List of Concrete Sealers. The surface treatment, including application rate, shall be applied in accordance with the requirements listed above and the Manufacturer’s recommendations. Metal hand rails shall be protected from spray by shielding or masking. The Contractor shall prohibit all pedestrian and vehicular traffic on the structure during the drying period of the protective coating.
601.13.1 1-Silane Treatment for Bridge Substructure: Before placing any steel
superstructure members on the concrete substructure units, the Contractor shall coat all exposed areas of the abutment, tops, sides, and all faces of pier caps an d pier stems to the ground or water line elevation with an approved silane based concrete sealer except for projects where concrete protective or other coatings are specified. Preparation of surfaces, application rates, and methods shall be as recommended by the silane manufacturer. Upon completion of all superstructure concrete curing operations, the Contractor shall remove all stains from substructure units using proprietary chemical stain removers and/or mild acid etching. Abrasive blast cleaning shal l be used to supplement the other cleaning methods to completely remove all stain s if the stained areas are severe or extensive. All cleaning methods shall be subject to approval of the Engineer. Re-coat all areas where stains were removed, regardless of the cleaning method used, with an approved silane based concrete sealer as specified above.
601.13.2 Epoxy Resin Protective Coating: The top surface of abutment bridge seats,
including drainage areas, and the adjacent bottom six (6) inches of the backwall and the top surface of pier caps which are located beneath expansion devices shall receive an epoxy resin protective coating. The area immediately beneath the bearing masonry plates may be omitted at the Contractor's option. Concrete surfaces to be coated shall be sound, dry and free of all laitance and curing materials. The coating shall not be applied until the concrete has attained the age recommended by the manufacturer. When required by the Engineer in the field, concrete surfaces shall be cleaned of all oil, grease and other potential bond inhibiting matter by acid etching with a 10 percent (10%) to 15 percent (15%) muriatic acid solution. The acid solution shall be spread and allowed to react until bubbling has subsided, approximately three to five minutes. The surface shall then be thoroughly flushed with clear water and allowed to dry. Where, in the opinion of the Engineer, acid etching is insufficient to clean the concrete, then sandblasting or an approved method of mechanical abrading shall be required. The exact indicated amounts of the base polymer and the reacting system, as recommended by the manufacturer, shall b e measured into mixing container and mixed thoroughly with a low-speed paddle-type mixer. After mixing, the material shall stand for an induction period of one hour before application. Following the one hour induction period, the mixed protective coatin g may be applied by brush, roller or spray. When applied by roller, a first quality, long nap roller is recommended for rough surfaces, and a short nap roller for smooth surfaces. If applied by spray, an externally atomized spray gun is recommended. If thinning is necessary for spray application, thinner shall be of the type and amount recommended by the coating manufacturer. Two coats of mixed material shall be applied in thin, uniform coats of approximately 2 to 3 mil dry film thickness each (4 -5 mil s wet thickness). The second coat shall be applied approximately 24 hours after the application of the first coat. One gallon of the system will cover approximately 275 square feet of smooth concrete, first coat; a second coat will cover approximately 400 square feet. In all cases application shall be made at temperatures recommended by the manufacturer.
601.13.3 Concrete Protective Coating: This section covers requirements for materials to
be used as surface finishes for designated surfaces of conc rete structures. The masonry coatings must hide form marks, patches, and other minor irregularities and prevent deterioration, spalling, and other damage to the concrete due to the action of the weather and deicing chemicals. The Engineer will inspect all concrete surfaces to be coated as stated in the plans and/or contract documents. The field painting (coating) of concrete structures shall follow the provided requirements set forth in this specification unless otherwise noted in the Contract. This spe cification shall apply to surface preparation, coating application, contractor responsibilities, environmental and worker protection, and waste handling/disposal. All structures shall be pre -cleaned and washed in accordance with Section 685 of the Specifications. The Engineer will ensure a satisfactory ordinary surface finish prior to coating operations. This section shall apply only when the pay item for concrete protective coating is included in the plans.
601.13.3 1-Physical Requirements of Coating: Physical requirements shall conform
to Section 711.5.2.
601.13.3 2-Concrete Surface Preparation: All concrete surfaces to receive a
protective coating shall be prepared in accordance with SSPC -SP 13, Surface Preparation of Concrete, SSPC-The Fundamentals of Cleaning and Coating Concrete, ASTM D4258 - Standard Practice for Surface Cleaning Concrete for Coating. All surfaces to receive a protective coating shall be thoroughly cleaned and kept free of oil, form o il, grease, dust, dirt, mud, curing compound, release agents, loose patching mortar, or any other substances that may prevent bonding.
601.13.3 3-Paint Application Requirements: The following surfaces shall be coated,
including all beveled edges.
1.Bridge Abutments and Wingwalls – Every exposed surface above a point six (6) inches below ground or fill line. Exclude where epoxy coating is applied.
2.Bridge Pier Caps – The tops (including exposed surfaces of pads, pedestals, and keys), sides and ends. Do not apply the coating to bearing areas. Exclude where epoxy coating is applied.
3.Bridge Superstructure – The tops, inside and outside faces, and ends of all barrier walls, parapets, curbs, and points that will be exposed. Do not apply the coating to the riding surface of the bridge deck.
4.Exposed Surfaces of Substructure and the Superstructure – all surfaces identified in 1), 2), and 3) above and the underneath surfaces of slab overhangs that are outside of exterior girders and the exterior side and bottom of exterior beams or girders, the interior windows of barriers, and all exposed surfaces of piers and abutments. Extend the masonry coating from a point six (6) inches below ground line to the top of the exposed surface.
5.Any other area as designated within the contract plans not mentioned above.
601.13.3 3.1-Weather Conditions: Painting shall not be done when the ambient
temperature is below 40°F or above 100°F, or the relative humidity above 90 percent (90%). Painting will only be permitted between the dates of April 15 th through October 15th . There will be no painting permitted to occur in a heated containment.
601.13.3 3.2-Paint Storage: Paint and thinners shall be stored in a temperature -
controlled environment between 40°F and 100°F. At no time will paint be used beyond the manufacturer’s shelf life.
601.13.3 3.3-Paint Application: The paint shall be applied by spray, brush or roller
methods. Brushes or rollers, when used, shall have sufficient body and length of bristle or roller nap to spread a uniform coat. Small touch -up areas may be brushed or rolled, if approved by the Engineer. Use of an agitated pot shall be mandatory in spray application. The agitator or stirring rod shall reach within one (1) inch, of the bottom of the pot and shall be in motion at all times during paint application. Coatings shall be mixed in strict accordance with the coating manufacturer’s written instructions. Under certain conditions, it may be necessary to thin or adjust the solvent balance of the paint. The type and amount of solvent to be used shall be that listed on the coating manufacturer’s product data sheet for that material. Upon thinnin g, the dry film thickness requirement shall still be met by appropriately increasing the wet film thickness. Application requirements and drying times between coats shall be in accordance with the manufacturer’s recommendations. Spray guns must be equipped with the recommended size tip for the paint product being applied and shall be held perpendicular (90 degrees) to, and at, the proper distance from the receiving surface. Complete protection shall be provided by the contractor against paint spatter, spillage, overspray, wind-blown paint, or similar releases. Appropriate containment shall be placed around the work area to protect public and private property. Staging must be adequate to provide access to all areas being painted. Violation of these requirements causing excessive paint waste will be justification for the WVDOH Engineer to order the Contractor to cease all work on the project until corrective action has been taken. The method of cleaning and/or replacement shall be submitted to the Engineer in advance for approval. Coating application shall be suspended any time the ambient temperature or the temperature of the concrete does not comply with the coating manufacturer’s recommendations. Prior to application of the materials, furnish the Engineer with copies of the coating material manufacturer’s brochures or booklets. Apply protective coating materials in strict conformity with the manufacturer’s written instructions and apply the material at a uniform rate of at least 50± 10 ft2/gal. Satisfactorily repair or remove any portions of the coating that are not clean, uniform in color, texture, thickness, tightly bonded, or that are damaged before final acceptance of the project and replace them with an acceptable finish and coating. Provide a neat uniform appearance, and prevent the coating from being dripped, sprayed, or otherwise deposited upon concrete and surfaces not designated to receive the coating. Remove any objectionable deposits or material and repair the surfaces to the Engineer’s satisfaction.
601.13.3 4-Environmental, Worker Protection, And Waste Handling:
601.13.3 4.1-General: Environmental protection shall be used when cleaning,
painting, welding or cutting an existing bridge. The containment class, emission assessment methods and levels as defined by the current revision of SSPC Guide 6 shall be as stated in the contract documents. The specific pollution control system which is proposed for the complete capture, containment, collection, and disposal of the “spen t material” generated by the work shall be included in the plan.
601.13.3 4.2-“Spent Material”: This shall include material generated by surface
preparation operations, and shall be disposed of in accordance with Section7 of SSPC SP-
13.The Contractor shall, at the Contractor’s expense, select a laboratory that will sample and analyze the “spent materials”. The laboratory must be certified by the WVDEP, EPA or by another state’s DEP-equivalent. Certification will be provided to the Engineer prior to the beginning of work. The waste transporter for both hazardous and non -hazardous waste will be listed on the Contractor’s Containment/Disposal Control Plan.
601.13.3 4.3–Permits for Disposal of “Spent Material”: Shall be in accordance with
Section 107.2, Permits, Licenses, and Taxes or any other applicable sections of Section 107. The “spent material” shall not be disposed of until authorized by the Engineer and in no case shall “spent material” be allowed to accumulate longer than 90 days prior to transport.
601.13.3 4.4-Additional Requirements for All Classes of Containment: Contractor
will provide ground covers beneath the containment area and all equipment where spills are possible to capture inadvertent spills or leaks of debris. Extend the covers a minimum of five (5) feet beyond the area to be covered. Debris shall be removed from the covers at least once per shift, or as directed by the Engineer. If the ground beneath the structure serves as the base of the containment, install and maint ain air and dust impenetrable materials such as solid plywood panels or flexible materials such as tarpaulins. Provide explosion–proof lighting inside containment for all paint application. Maintain a minimum of ten (10) foot-candles for surface
601.13.3 5-Contractor Responsibilities:
601.13.3 5.1-Concrete Protective Coating Materials: Select masonry coatings from
the Department’s List of Approved Materials. Use a material that is readily recognizable by its name, trademark, container, or other feature. All materials shall conform to subsection 711.5.3.
601.13.3 6-Inspection Requirements:
601.13.3 6.1-Inspection of Applied Paint : If in the opinion of the Engineer the
coating has flaws other than deficiencies in the prescribed dry film thickness, the material shall be repaired or shall be removed and replaced. Defects in the film, including but not limited to runs, sags, mud -cracking, lifting, overspray, and dry spray, shall be corrected until a continuous uniform film has been applied. Excessive film thickness shall be reduced and insufficient film thickness shall be increased. If the thickness of the finish coat is reduced, a thin coat of the finish shall be reapplied to seal the surface and to blend the area into the surrounding coating. Depending on the defect, total removal and replacement of the effected coating may be required. No unsightly runs or sags shall be visible. All "mud -cracking" and/or "dry overspray" in the paint film shall be removed. Calibration of the thickness g age and dry film thickness measurements shall be in accordance with MP 708.40.00.
601.13.3 6.2-Access for Inspection: The Contractor shall furnish suitable safe access
and shall provide a time mutually agreed to for inspecting the structural concrete p rior to and after each coating. The Division’s inspector shall approve all repairs. When providing suitable safe access, rubber rollers or other protective devices shall be used. Metal rollers or clamps and other types of fastenings that will mar or dam age freshly coated surfaces shall not be used. No temporary attachments, supports for access, or forms, shall damage the coating system. Any damage that occurs from such devices shall be repaired to the satisfaction of the Engineer at the Contractors expense.
601.13.3 6.3-Repair Procedures for Field Paint Deficiencies: All field repairs to the
coating shall be made in strict accordance with the coating manufacturer's recommendations, except where the requirements listed in this specification are more stringent. Any products used during repairs to the coating deficiencies shall be from the same manufacturer as the coating being repaired. Surfaces that will be inaccessible for coating after erection shall be repaired and/or recoated prior to erection. The Engineer is to review and accept a repair plan before deficient areas are repaired. The requirements specified herein for provisions for inspection, mixing, thinning, temperature and humidity, and application shall govern the coating of the repaired area s. In order to avoid abrupt changes in paint thickness, the area adjacent to repair areas shall transition from zero paint thickness to full system thickness within not less than three (3) inches of the repair area by means of sanding the transition area. The requirements for the dry film thickness of the repair coats are the same as those specified for the paint system.
601.13.3 7-Submittals: Submittals shall be forwarded through the Prime Contractor
and be accepted by the Engineer prior to commencemen t of the subject work. This is the responsibility of both the Fabricator and the Field Contractor. Electronic submittals will be accepted.
601.13.3 7.1-Quality Control Plan for Painting: Minimum requirements and
document form are set forth in MP 688.02.20.
601.13.3 7.2-Containment/Disposal Environmental Control Plan for Existing
Concrete Structures: Minimum requirements and document form are set forth in MP 688.03.20.
601.14 Method of Measurement:
The quantity of work done for Classes A, B, C, D, H, K, and M concrete will be measured in cubic yards, complete in place and accepted as determined by the dimensions on the Plans or Contract Documents, subject to adjustments provided for in Sections 104.2 and 109.2. The quantity of work done for Class H and Class K concrete will be measured in cubic yards, complete in place and accepted, as measured from one end of the bridge to the other, fascia to fascia, and from the top of the forms to the finished elevation of the proposed deck surface. The volume of concrete required to fill the flutes of stay -in-place forms shall be calculated by taking the Contractor’s approved SIPadj factor and multiplying by the square yardage of SIP area minus beam widths, expansion dam widths, etc. as applicable. No deductions will be made for the volume occupied by pipe less than eight (8) inches in diameter, nor for reinforcing steel, anchors, conduits, weep holes or piling, or other small inserts. The cost of copper, copper -nickel alloy or other type of flashing, expansion joint filler, preformed joint filler, concrete bearing pads, drain pipes for weep drains through abutments, wings and walls or bridge floors, unless otherwise specified, shall be included in the unit prices bid for the several classes of concrete. All costs associated with the revised mix design and proportions shall be in the unit price bid for the class of concrete designated as modified. All costs associated with architectural formwork shall be in the unit price bid for the class of concrete designated as architectural. No deductions will be made for the volume oc cupied by the architectural formwork. The quantity of work done under line items subsection 603.13.3 will include preparation and application of concrete protective coating to all exposed surfaces of special bridge railing, outside face of exterior prestr essed girders, exposed portion of abutments, wingwalls and piers. The area to be coated will be measured on a square foot basis.
601.15 Basis of Payment:
601.15.1 General: The quantities, determined as provided above, will be paid for at the
contract unit prices bid or at the adjusted percent of contract price as specified for the items listed below, which prices and payments shall be full compensation for furnishing all t he materials and doing all the work prescribed in a workmanlike and acceptable manner, including all labor, tools, equipment, joint filler, field laboratory, supplies and incidentals necessary to complete the work. The cost of stay-in-place fabricated metal forms and all work associated therewith shall be included in the unit price bid for concrete placed as the bridge deck. The amount of concrete required to fill the form flutes is included in the plan quantity of the concrete bridge deck material, and shall be paid for per Section 601 of the Specifications. The quantities determined as provided above, complete in place, will be paid under item 601019-* concrete protective coatings on a square foot basis. No additional payment will be allowed for con creting under adverse weather conditions nor when the use of a higher class concrete than that specified is permitted.
601.15.2 Price Adjustments: The Contractor will be assessed equitable deductions of
twenty-five dollars ($25.00) per square foot for areas of bridge decks not meeting the specified ⅛ inch tolerance and not specified to be removed nor directed to be ground, and for any areas that have been ground but do not meet the specified tolerance. Deviations will be tested with a ten (10) foot rolling straightedge or using certified inertial profiler and operator (See Section 720.2). Inertial profiler data will be analyzed by using the rolling straight edge simulation on ProVal Software. Concrete not found in compliance with the requirem ents of subsection 601.4.4 for compressive strength will be paid for at a reduced contract price in accordance with the following formula: f’c-X Percent Reduction = 0.6f c - Where: f c = Design Strength, psi X = Observed Strength, psi = Standard Deviation The percent reduction shall be applied to the sublot with the low strength.
601.16 Pay Items:
ITEM DESCRIPTION UNIT 601001-* Class A Concrete Cubic Yard 601002-* Class B Concrete Cubic Yard 601003-* Class K Concrete Cubic Yard 601003-* Class K Concrete, Architectural Cubic Yard 601005-* Class C Concrete Cubic Yard 601006-* Class D Concrete Cubic Yard 601009-* Class H Concrete Cubic Yard 601019-* Concrete Protective Coating Square Foot 601025-002 Modified Concrete, Class A Cubic Yard 601025-003 Modified Concrete, Class B Cubic Yard 601025-005 Modified Concrete, Class C Cubic Yard 601025-006 Modified Concrete, Class D Cubic Yard 601025-007 Modified Concrete, Class H Cubic Yard 601025-008 Modified Concrete, Class K Cubic Yard 601026-002 Modified Architectural Concrete, Class B Cubic Yard 601026-003 Modified Architectural Concrete, Class H Cubic Yard 601026-004 Modified Architectural Concrete, Class K Cubic Yard 601046-* Modified Concrete End Post Each * Sequence number
Referenced in this section
Structural Concrete in other states
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Source: Standard Specifications for Roads and Bridges, 2023 Edition. Pages 325–373 of 1,006. View official source ↗