UDOT Construction Inspection Guide - Chapter 6

Published November 2012

UDOT Construction Inspection GuideConstruction Inspection GuideCHAPTER 6: Structures

Table of Contents

Structures

Structural Foundations, Excavation & Backfill 02056 – Str. Embankment, Backfill Borrow This section covers inspection of the structural backfill items for bridges, box culverts… 02221 – Remove Structure & Obstruction To remove all structures and obstructions, the contractor must remove, dispose of, or… 02455 – Driven Piles This item includes specifications for the materials, fabrication and installation of driven piles…. 02466– Drilled Shafts This item includes specifications for the materials, fabrication and installation of drilled shaft foundations…. 02832S – Select Backfill for MSE Walls Mechanically stabilized earth (MSE) is soil constructed with artificial reinforcing, used for….

6.3

Structural Elements and Materials The most common of structural materials is concrete and steel. This section addresses the most common structural materials and its use on major …. 02645 – Precast Concrete Culverts This item includes the materials, fabrication and placement for precast concrete box culverts… 02646 – Concrete Box Culvert This item includes the materials and construction of cast in place concrete box culverts… 02861 – Precast Retaining/Noise Walls This item includes the materials, fabrication and placement for precast noise retaining walls… 02893 – Overhead Signs/VMS Structures This item includes the materials, fabrication and installation of structural steel materials used… 03211 – Reinforcing Steel and Welded Wire This item includes the materials and placement for reinforcing steel and welded wire fabric used in… 03310 – Structural Concrete This item includes the materials and placement for structural concrete for cast in place applications… 03390 – Concrete Curing This item includes the specifications for the curing of concrete specific to concrete structures…. 03392 – Penetrating Concrete Sealer This item includes materials used as a preventive treatment to seal water and deicing salts…. 03412 –Pre-stressed Concrete This item includes the materials and placement for structural concrete that includes pre-stressed…. 05120 –Structural Steel This item includes specifications for the materials, fabrication and installation of structural steel…. 05822 –Bearings This item includes the materials and placement for bearings used in conjunction with bridge girders… 09972 – Painting Structural Steel This item includes specifications for the materials and application of painting systems for structural….

Structures Introduction Bridges, retaining walls, culverts & other structures play a major role in UDOT’s transportation system… Prosecution and Progress 00555 – Project Schedule

The purpose of this section is to provide basic guidance to schedule of work. Limitations to ….

6.1 6.4

Structural Survey Survey is a critical component of structural work and ahs a direct impact on structural geometry, load capacity, clearances….

6.2

Structural Repairs and Modifications 03605 – Approach Slab Jacking This item includes the materials and construction requirements for lifting (jacking) of bridge…. 03924 – Structural Concrete Repair/Sealing This item includes the materials and construction requirements for repairs and rehabilitation to …. 03932 – Concrete Slope Protection Repair This item includes the materials and construction requirements for repairing slope protection…. 03933- Parapet End Modification This item includes the materials and construction requirements for repairs to bridge parapet ends …. 03934 – Structural Pothole Patching This item includes the materials and construction requirements for repairs and patching of potholes…. 05831 – Expansion Joint Modification This item includes the materials and construction requirements for replacement of bridge expansion…. 07921 – Sealing Existing Concrete Slope Protection This item includes the materials and construction requirements for sealing slope protection…. 07922 – Relief Joint Crack Sealing This item includes the materials and construction requirements for sealing concrete relief joints…. 09991 – Cleaning & Repainting Structural Steel This item includes the materials and construction requirements for cleaning and repainting …. 09992 – Cleaning and Overcoating Structural Steel This item includes the materials and construction requirements for cleaning and overcoating….

6.6

Table of Contents - Continued

Bridge Decks, Approaches and Joints 02982 –Bridge Concrete Grinding This item includes procedures for grinding new concrete deck and approach slabs systems. Grinding of the… 03311 – Joint Closure A bridge deck joint closure consists of removing the existing joint system, installing reinforcing steel and … 03339 – Precast Concrete Deck Panel Precast deck panels are used on both new construction and deck replacement projects ….. 03372- Thin Bonded Polymer Overlay This item includes procedures for overlaying concrete bridge decks with a thin polymer material and …. 05832 – Expansion Joint This item includes the materials and placement for expansion joints and associated forming false work …. 05835 – Modular Expansion Joint This item includes the materials and placement for modular expansion joints and associated forming…. 07105 – Waterproofing Membrane This item includes procedures for applying a waterproofing membrane for bridge decks and….

6.5

CHAPTER 6: STRUCTURES

Page | 1UTAH DEPARTMENT OF TRANSPORTATION

CHAPTER 6: STRUCTURES

6.0 INTRODUCTIONBridges, retaining walls, culverts and other structures play a major role in UDOT’s transportati on system. They directly infl uence traffi c operati ons, safety and funding needs. The quality of structural constructi on can have a tremendous eff ect on the life and safety of these structures. Constructi on Engineers and Inspectors play a vital role in ensuring that structural projects are built to plans and provide expected performance.

The secti ons of this Structures Chapter closely follow the corresponding secti on in the Standard Specifi cati ons. The intent of this chapter is not to repeat the specifi cati ons, but to off er an overview of the general intent of the specifi cati on, and guidelines for Inspectors to ensure work has been properly completed. All secti on numbers refer to the Standard Specifi cati ons 2012 editi on and Supplements.

The fi rst duty of an Inspector is to become thoroughly familiar with the contract plans, standard plans, special provisions, standard specifi cati ons, and any right-of-way agreements that apply to the parti cular project. Each secti on of this chapter is referenced to a specifi c standard specifi cati on and includes descripti ons for the following:

General Overview

Briefl y describing the related work and intent of the specifi cati ons, and common issues for related secti on covered.

Pre-Constructi on Checklist

Summarizing necessary documentati on that must be submitt ed with the related secti on prior to constructi on of the item.

Inspecti on Checklist

Describes the acti ons the Inspector should take during constructi on acti viti es to ensure that the item is properly constructed and documented.

Chapter 6

UDOT Construction Inspection GuideConstruction Inspection Guide

Page | 2 CHAPTER 6: STRUCTURES

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Level One 1. Plans, Specs and Esti mates

2. Role of the Inspector

3. Structural Concepts

4. Structural Geometry and Layout

5. Structure Types and Terminology

Terminology: (Structures)

Terminology for bridges, retaining walls, culverts and other structures can be very confusing. The following graphics show common terminology of bridge elements:

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CHAPTER 6

UTAH DEPARTMENT OF TRANSPORTATION

6.1 PROSECUTION AND PROGRESS – GENERAL INTRODUCTIONStructural work can be the primary scope of a project or a component of a broader project. In either situati on, the requirements of the prosecuti on and progress secti on of the project need to be reviewed and implemented. The schedule and limitati ons of operati ons for the structural work are important factors in the success of the project. For example, many structure projects are now using techniques such as accelerated bridge constructi on with limitati ons to traffi c closures. The Inspector has a responsibility to understand and enforce these requirements.



A) PROSECUTION & PROGRESS - SECTION 00555

General

The purpose of this secti on is to provide basic guidance to schedule of work, limitati ons to work and payment schedule.

Contractor Submitt als

The contractor must submit a baseline project schedule within 14 days of noti ce of award for approval by the Engineer using a Primavera 5.0 or other approved format.

Documentati on and Payment

All Inspectors should be familiar with inspecti on and documentati on requirements for prosecuti on and progress including project schedule and limitati ons of operati ons. A schedule for payments is also required.

Pre-Inspection Submittals & Items Contractor must submit a baseline project schedule within 14 days of notice of award and prior to starting work. The project schedule should include components for major structural work such as excavation, foundations, superstructure erection, and backfi ll. The baseline schedule must be reviewed and accepted by the Engineer prior to beginning work.

Contractor and Inspector should be familiar with project plans and specifi cations relating to schedule and limitations of structural work items.

The Inspector and contractor must be familiar with any requirements for accelerated construction methods. They are encouraged to contact UDOT’s structures division for any questions.

Inspection & Field Documentation Contractor and Inspectors must have copies of the plan package including plans, standard specifi cations and special provisions readily available in the fi eld for review and interpretation of issues as they arise.

Inspectors must maintain daily inspection records giving a narrative of work accomplished, and resources of labor, equipment and materials used. The Inspector diaries may become an important document in the event that the project schedule changes and change orders are required.

Coordinate all accelerated bridge construction work with UDOT’s Structures Division.

00555: PROSECTUTION & PROGRESS

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CHAPTER 6


6.2 STRUCTURAL SURVEY – SECTION 01721

General

Survey is a criti cal component of structural work and has a direct impact on structural Geometry, load capacity, clearances, drainage, ride and safety. The inspector should be familiar with the requirements of standard specifi cati on 01721 (Survey) as it pertains to structural items including drainage structures, bridges, box culverts and retaining walls. In many cases, survey accuracy and tolerances may be greater for structural work than roadway and other items. For example, bridges are typically designed and dimensioned on plans to a 1/16th of an inch. Small survey errors have the potenti al for signifi cant problems with overall fi t and clearance of a bridge or other structure.

Structural plans typically will show dimensions using a variety of perspecti ves including plan views (looking down), elevati on views (looking from side), and cross secti ons. Dimensions of these perspecti ves are adjusted to include slope, curvature and profi le. Some of the most common fi eld errors relati ng to structural geometry are those associated with errors in misinterpretati on of plan dimensions. It is important for the surveyor and Inspector to understand and review the plans and to ask questi ons if needed, especially when uti lizing precast elements.

Since approximately 2005, UDOT has increased its use of precast deck panels and other precast components. The fi t of these components requires even greater precision than cast in place constructi on. The Inspector and Resident Engineer should pay parti cular att enti on to survey practi ces for precast elements.

Submitt al Requirements and Common Issues

The contractor is responsible to submit a writt en descripti on of the survey plan including manpower, equipment and data storage prior to starti ng survey work.



6.3 STRUCTURAL FOUNDATIONS, EXCAVATION AND BACKFILL

A) EMBANKMENT, BORROW AND BACKFILL (STRUCTURAL) – SECTION 02056

General

This secti on covers inspecti on of the structural backfi ll items for bridges, box culverts, foundati ons, pipe culverts, retaining walls, drains and other structures. See standard specifi cati on 02317 for related requirements for Structural Excavati on. The stability of a structure is directly related to having adequate backfi ll materials to support the structure.

Pre-Inspection Submittals & Items Contractor must submit a survey plan prior to starting work containing anticipated personnel, equipment, methodology and data storage processes.

Inspector to communicate survey efforts with UDOT’s Central Materials and Structures Divisions for structures using precast components.

Inspection & Field Documentation Inspector to observe structural survey and notify the Engineer and Contractor of any potential problems found with general structural layout, geometrics, vertical clearance, horizontal clearance and other related issues.

Inspector is to document survey work activities.

Inspector to document any fi t problems or issues with the fi t of precast components.

01721: STRUCTURAL SURVEY

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CHAPTER 6


The use of acceptable materials that are compacted to proper tolerances is an important component of structural constructi on. In parti cular, this is criti cal to structures without deep foundati ons such as pipes, retaining walls and bridges on spread footi ngs. The Inspector plays a vital role in ensuring the quality of materials and constructi on methods for structural embankment, backfi ll and borrow.

Pre-Inspection Backfill Materials: Ensure that temporary erosion control measures are in place, SWPPP materials used have been certifi ed, maintained throughout construction, and subsequently removed after completion.

Site Preparation: Clearing and grubbing within the designated area is completed before starting excavation. No organic material remains that could contaminate the embankment or backfi ll. Refer to Section 02231.

Safety: Contractor submitted proposed method of blasting, delay pattern, explosive types, and type of blasting mat cover, if applicable. Contractor has complied with all applicable regulations when excavating and trenching, such as the shoring system standards established by OSHA. Refer to Section 00820. If applicable, contractor provided a cofferdam for underwater work and removed all cofferdams, sheeting, and bracing when no longer needed.

Inspection Excavation and Disposal: Contractor has furnished copies of disposal permits or agreements, or letter certifying the destination of the material, if applicable.

Materials Inspection: Materials are tested in accordance with the MS&TR and material placement is in conformance within specifi ed lift thicknesses and compaction requirements. Finish to the design grade and within specifi ed tolerances.

Use of On-Site Materials: Contractor obtained written approval before using excavated materials found on the work site that are suitable for completing other bid items of work and before excavating material outside grading limits. Contractor established an approved method of measuring quantity of on-site material used.

Documentation: The Inspector along with the Materials Testing Technician shall take measurements for compaction of the backfi ll materials and document that minimum requirements have been met.

02056: EXCAVATION & BACKFILL



B) REMOVE STRUCTURE AND OBSTRUCTION - SECTION 02221

General

To remove all structures and obstructi ons, the contractor must remove, dispose of, or salvage buildings, fences, structures, pavements, curb, gutt er, driveways and approaches, sidewalk and similar hard surfaces, abandoned pipelines or uti lity items and other obstructi ons that interfere with constructi on. This includes obstructi ons such as foundati ons, bridges, culverts, guardrail, concrete work, septi c tanks, and trees. The contractor should salvage as specifi ed in the plans, or dispose of in a manner approved by the Engineer.

The Inspector should ensure that the contractor has removed all organic materials in any areas to be backfi lled or compacted and assure the quality of the underlying materials.

Submitt al Requirements

Prior to constructi on, request copies of the following documents:

1. Uti lity Locati on and Protecti on (Blue Stakes receipt form).

2. Documentati on for Wasted Materials Disposal.

3. Environmental Control requirements, including SWPPP certi fi cati ons.

4. Demoliti on Permits from the Health Department or local government.

Common Issues

Document these common contractor mistakes:

1. Grade not cut to the required tolerance.

2. All organic materials and obstructi ons are not removed.

3. Improper material disposal, on or off site.

4. Drainage is not maintained.

5. Contaminati on of materials to be left on-site for future use.

6. Remaining grade will not support new structure.

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CHAPTER 6


C) DRIVEN PILES - SECTION 02455

General

This item includes specifi cati ons for the materials, fabricati on and installati on of driven pile foundati ons. Driven piles are commonly used on bridge structures to transfer the weight of the bridge to suitable soils and earth materials. In additi on, they resist movement of the bridge during earthquakes. Poor quality of the pile materials and installati on can result in sett lement and possible collapse of the bridge. The Inspector plays a vital role in the quality of driven pile constructi on.

Pile Materials

Driven piles can be made of steel, ti mber or concrete. The most common piles used are steel, and commonly installed using circular (pipe shape) or H shaped beams (H pile). Requirements for the material properti es of the piles are shown in the bridge plans and are criti cal to their ability to support

Pre-Inspection Contractor has obtained all necessary local government permits for demolition, as required when demolishing buildings or homes.

Inspection Obstructions are removed to required depth below surface or broken to required size limits if allowed to remain in place.

Organic materials have been removed and the quality of the underlying materials has been assured.

Areas are backfi lled and compacted as specifi ed.

02221: REMOVE STRUCTURE & OBSTRUCTION



the bridge. The Inspector and Resident Engineer should contact a Structural Engineer before allowing any substi tuti on of pile materials or shapes other than what is shown on the plans. Contractors will oft en ask to substi tute pile shapes, thicknesses and grade for cost or availability reasons. However, small changes in wall thicknesses or grade of steel can have dramati c impacts on the pile capacity. The contractor is required to submit material certi fi cati ons prior to delivery of the piles.

Buy America requirements apply to Federally funded projects.

Pile Capacity

Driven piles support the bridge loads through a combinati on of bearing capacity at the ends (ti p) and side fricti on with the soils along the sides of the pile. Piles are driven by mechanical equipment (pile driver). The pile driving operati on loosens (liquefi es) the soil as the pile is being driven. Once the pile driving has been completed, the soils will swell against the pile resulti ng in a higher load capacity than when the pile is being driven. The piles ability to support weight is measured by electronic equipment called a Pile Driving Analyzer (PDA). The PDA is used to take measurements on a test pile while driving and again (re-strike) at least 24 hours later when the surrounding soils have fi rmed up.

The bridge plans typically show an esti mated driving resistance and a minimum pile resistance that must be reached at “re-strike”. Bridge plans will also show the esti mated number of piles, layout and driving elevati ons. Bridge foundati ons are designed to resist the calculated weights (loads) of the bridge in comparison to expected soil conditi ons. However, soil capaciti es can vary dramati cally and the actual pile depths and quanti ti es may vary from what is esti mated on the plans. The Pile Driving Analyzer is used on a “test pile” to determine the actual pile capacity depths and quanti ti es. The Inspector needs to take blow count readings quanti fying the number of blows required to drive the pile for at least 1 foot increments. The blow counts are compared to the test pile to correlate to actual resistance readings.

Driving Equipment

The type and size of hammer used to drive piling needs to match the size and strength of the pile being driven. This is similar to using a hammer size that matches the size of a nail being driven. Too small of a hammer may not be able to effi ciently drive the pile, and too large of a hammer may damage the pile. The contractor is required to submit a detail of pile driving equipment that they will be using for approval. This informati on will also be needed for the PDA

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CHAPTER 6


to measure the capacity of the pile. Inspectors should document the pile driving equipment being used and take photographs.

Certi fi cati ons

Material certi fi cati ons are needed for the driven piles. Most driven piles are made of structural steel and are commonly available in standard shapes, grades and dimensions from both domesti c and foreign manufacturers. Steel is manufactured by a steel mill (manufacturer) from raw materials into common shapes and sizes. A steel supplier or fabricator typically resells, reshapes or modifi es the steel into the fi nal shape and confi gurati on. The steel producti on mill and fabricator may or may not be the same company and the Inspector is responsible for certi fi cati ons for both the materials and fabricati on process.

Certi fi ed Mill Test Reports (MTR) must be submitt ed for all structural steel materials, including those manufactured outside the United States. Additi onal “Buy America” requirements apply for Federally funded projects or if specifi ed. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certi fi ed if components are used on a bridge structure.

UDOT’s Central Materials Division oversees the quality process for the manufacturing and fabricati on of structural steel items. The Resident Engineer and Inspector are responsible to noti fy them of structural steel items used on the project.

Steel piles commonly are available in lengths less than 50 feet to assist in shipping. Welding of pile secti ons is commonly required. Welding should be performed by welders who are certi fi ed by the American Welding Society (AWS) for structural steel AWS d1.1 or higher.

Unloading, Handling and Storing Upon delivery of the piles, the Inspector should look for signs of damage and verify that the material informati on matches what is shown on the mill certi fi cati ons. Any discrepancies should be brought to the att enti on of the Resident Engineer. The unloading of the steel should be accomplished by means of equipment and methods



which will not damage the members and should be moved by use of slings and wood blocks to prevent damage to the fl anges. Steel members are never to be dropped. Piles should be stored in a manner that will prevent injury from moving or falling.

Constructi on

Driven piles should not be driven unti l the excavati on is complete unless specifi ed on the plans. The Inspector should ensure that any exposed side slopes meet OSHA safety standards. The piles are to be driven in a verti cal alignment unless noted otherwise.

Welding of pile secti on must be performed by a certi fi ed welder. During the driving operati ons, the Inspector should visually look for signs of distorti on of the pile or misalignment. Any concerns should be brought to the att enti on of the Resident Engineer. A minimum of 2" of exposed pile should extend above the ground and into the bott om of the abutment.

Test Pile and Acceptance

The contractor is required to drive a test pile prior to driving additi onal piles and compare actual resistance to ensure it meets or exceeds the design resistance. Resistance readings are measured by an independent testi ng fi rm who is approved by UDOT. Blow counts should be taken and recorded for every foot of the test pile. If the minimum resistance can’t be reached at the re-strike a Structural Engineer should be contacted for further instructi ons such as adding additi onal piles or driving to a deeper depth.


The contractor shall submit the following for approval:

1. Project Schedule with milestones for driven piles.

2. Buy America certi fi cati on (if applicable).

3. Material certi fi cati ons, and mill test reports (MTR).

4. Certi fi cati ons of Welders.

5. Pile Driving Equipment data.

6. Selecti on of approved Pile Driving Analysis fi rm.

7. Buy America Certi fi cati on/Documentati on.

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CHAPTER 6


Common Issues1. Missing approvals and certi fi cati ons.

2. Contractor wants to substi tute with diff erent pile shapes and sizes.

3. Damage of piling during shipment or placement.

4. Improper welding, cutti ng, bending or modifi cati on in fi eld.

5. Improper fi t or alignment.

6. Excessive defl ecti on, movement or stability.

Pre-Inspection Contractor to Submit Project Schedule including pile driving tasks.

Contractor to Submit Mill and Material Certifi cations.

Contractor to submit Pile Driving Equipment using UDOT form.

Contractor to submit certifi cations for welder qualifi cations.

Selection of an approved Pile Driving Analysis Firm.

Safety Plan for handling piles and driving process.

Field Inspection & Documentation Visual verifi cation of piles for damage or defects.

Inspector to document and verify fabrication certifi cation with pile labels.

Pile alignment.

Splice details and welding procedures.

Maintain records of drill depths, conditions and quantities used.

Contact Structural Engineer for any abnormal issues.

02455: DRIVEN PILES



D) DRILLED SHAFTS - SECTION 02466

General

This item includes specifi cati ons for the materials and constructi on of drilled shaft foundati ons. Drilled shaft foundati ons are commonly used on bridge structures to transfer the weight of the bridge to suitable soils and earth materials. In additi on, they resist movement of the bridge during earthquakes. Poor quality of the drilled shaft can result in sett lement and possible collapse of the bridge.

Drilled Shaft Constructi on

Drilled shaft foundati ons are constructed by mechanically drilling a shaft into the earth and placing a reinforcing steel cage and fi lling with concrete. The reinforcing extends into the

abutment or foundati on footi ng to transfer the load from the bridge. The Inspector and Resident Engineer are responsible to ensure that the shaft is safely drilled to the recommended depth and quality using approved materials. The Inspector should ensure that the materials are certi fi ed, shaft alignment is true, and reinforcement and concrete are properly placed. The Inspector should also ensure that concrete has cured a suffi cient amount of ti me before drilling an adjacent shaft .

Drilled Shaft Materials

Drilled shaft s are strengthened by adding reinforcing steel and concrete. The reinforcing steel must meet material specifi cati ons and certi fi cati ons as specifi ed in secti on 03211. The concrete must meet approved mix designs and testi ng during placement for Portland cement concrete as described in secti on 03055.

Drilling Equipment

The contractor is required to provide equipment that can safely and effi ciently drill holes to the required depth, diameter, and alignment. The use of steel casing is

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CHAPTER 6


commonly used to prevent the shaft s from collapsing during drilling. The drilling equipment should also be capable of removing the casing.



1. Procedures for placing concrete under water.

2. Certi fi cati ons for reinforcing steel.

3. Mix design for concrete.

Common Issues1. Certi fi cati ons and procedures not submitt ed on ti me.

2. Equipment breakdowns.

3. Shaft sides collapse aft er drilling and removal of casing.

Pre-Inspection Concrete Mix Design approved.

Reinforcing Steel approved.

Procedure for Placing under water.

Field Inspection & Documentation Drilled to estimated depth.

Shaft straight and true.

Materials testing of concrete.

Proper placement of concrete and vibration.

Maintain records of blow counts, driven depths and quantities used.


02466: DRILLED SHAFTS



E) SELECT BACKFILL FOR MSE WALLS - SECTION 02832S

General

Mechanically stabilized earth (MSE) is soil constructed with arti fi cial reinforcing. It can be used for retaining walls, bridge abutments, dams, seawalls, and dikes. Only select backfi ll should be used for MSE retaining walls. The reinforcement materials of MSE can vary widely from steel grids to geotexti les. The Inspector should ensure that materials used meet plan specifi cati ons and that density requirements are met.


Prior to performing inspecti on, request copies of the following documents:

1. Approved job mix formula (gradati on targets).

2. Weight Tickets for Measurement & Payment.

Common Issues

Document these common contractor mistakes:

1. Material placed on snow or frozen grade.

2. Drainage is not maintained.

3. Lift thickness or moisture is incorrect.

Approved job mix formula.

Density requirements have been met.

Soil classifi cation, gradation, and other soil requirements satisfy the materials specifi cation.

Material placement in conformance within specifi ed lift thickness.

02832: SELECT BACKFILL FOR MSE WALLS

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6.4 STRUCTURAL ELEMENTS AND MATERIALS – GENERAL INTRODUCTIONThe most common of structural materials are concrete and steel. This secti on addresses the most common structural materials and its use on major structural elements such as culverts, girders and other components.

A) PRECAST CONCRETE BOX CULVERTS - SECTION 02645

General

This item includes the materials, fabricati on and placement for precast concrete box culverts. These structural systems are pre-fabricated using reinforced concrete materials. Cast in place box culverts are addressed in other specifi cati ons. Associated work may include cast in place concrete for wing walls and other components.

Precast box culverts are commonly used as buried drainage structures to convey water underneath the roadway. They are also used as pedestrian, wildlife and uti lity structures. Precast systems off er advantages such as an alternati ve where ready mix concrete suppliers are not available or constructi on schedules are limited. Disadvantages include separati on and leaking of joints if they are not properly installed.

Precast box culverts consist of reinforced concrete secti ons that are shipped to the project

site and joined to achieve the desired culvert length. Fabricati on is typically completed by a pre-approved fabricator and inspected for approval by UDOT’s Central Materials Division prior to shipment. UDOT’s central materials division is responsible for the quality control of the pre-casti ng process including materials, forming, casti ng and curing of precast concrete structural components. As such, the Resident Engineer or Inspector should noti fy UDOT’s central materials and structures division of contractor schedule to fabricate precast culvert systems. The Resident Engineer will receive “shop drawings” submitted for approval prior to fabricati on. The Resident Engineer is responsible to forward the SE drawings to the designer of record and also noti fy UDOT’s central materials and structures divisions.



Once cured and approved, the precast components will be shipped with a label certi fying the quality and approval. The fi eld Inspector should verify the presence of this acceptance label prior to placement on the project site. Once the fi nished product leaves the precast yard, it becomes the responsibility of the fi eld Inspector who will ensure that the component is handled properly and not damaged.

The Inspector will need to ensure that the bedding surface and materials are properly prepared prior to placing the culvert segments. He/she will ensure that each segment is properly fi t with adjacent segments, joint materials properly installed, and the structure is backfi lled to specifi cati ons. The Inspector should ensure that the culvert is installed to dimensions and specifi cati ons in the plan package. This includes proper depths, cover, fl ow, and joint tolerances.


Prior to fabricati on and installati on, the contractor shall submit the following:

1. Project Schedule that included milestones and dates for the fabricati on, shipping and placement of precast concrete structural components.

2. Shop Drawings for approval of Precast components by the Design Engineer with noti fi cati on to UDOT’s Structures Division.

3. Noti fi cati on to UDOT’s Central Materials Lab and Resident Engineer of schedule to form and cast the precast components.

4. Certi fi cati on of materials and fabricati on process to be approved by UDOT Central Materials Division prior to fabricati on.

5. Erecti on Plan.

Common Issues

Document these common contractor issues:

1. Shop Drawings are missing or delayed.

2. Approvals, certi fi cati ons, and inspecti on not coordinated with Central Materials, lead designer or Structures Division.

3. Finish of concrete is substandard.

4. Grade is not adequately prepared or compacted.

5. Finished product is damaged during shipment or placement.

6. Structural component is not lift ed or placed in a safe manner.

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CHAPTER 6


7. Joints are not properly fi tt ed to acceptable tolerances.

8. Contractor fails to compact backfi lling materials.

9. Components are not installed to acceptable dimensions or fi t.

B) CONCRETE BOX CULVERTS - SECTION 02646

General

This item includes the materials, and constructi on of cast in place concrete box culverts. Precast box culverts are addressed in other specifi cati ons. Associated work may include constructi on of wingwalls, forming, shoring and backfi lling. Buy America requirements apply to Federally funded projects.

Cast in place box culverts are commonly used as buried drainage structures to convey water underneath the roadway. They are also used as pedestrian, wildlife and uti lity structures. Cast in

Pre-Inspection Contractor to submit project schedule that includes precast items.

Contractor to Submit Shop Drawings for approval.

Inspector to coordinate inspection with UDOT Lead Designer, Central Materials and Structures Division.

Central Materials Inspector to ensure materials certifi cations, mix designs, forming, placement, curing and overall fabrication process.

Fabricator to ensure that incidental items such as parapet ties, fence post, anchor bolts and other details are included prior to casting concrete.

Erection Plan is required prior to placement.

Field Inspection & Documentation Central Materials to certify fabrication and approval of component.

Inspector to document and verify fabrication certifi cation.

Ensure bedding material is properly constructed and compacted.

Ensure components are properly shipped and placed.

Ensure joints are properly installed to acceptable tolerances.

Ensure proper fi t and construction to acceptable dimension tolerances.

Maintain documentation of fabrication, certifi cations and placement.

02645: PRECAST CONCRETE BOX CULVERTS



place systems have proven to be one of the most durable structure types if properly constructi on and can last for more than100 years. Constraints of cast in place culverts include the availability of ready mix suppliers, quality of constructi on in the fi eld, and additi onal ti me to construct.

Cast in place concrete box culverts consist of preparing a sub-base, placement of reinforcing steel, forming and placement of concrete. The Inspector is responsible to ensure that materials, constructi on and safety processes meet specifi cati ons.

Box culverts are typically buried structures that require excavati on. The Inspector should ensure that excavated slopes are laid back to meet OSHA standards with acceptable egress access points. The sub-grade needs to be prepared to the proper dimensions and compacted to tolerances. Materials such as reinforcing steel require certi fi cati on and verifi cati on of proper placement in the fi eld. Concrete requires approval of mix designs, proper placement and materials testi ng in the fi eld. Backfi ll materials need to meet specifi cati ons and are to be compacted to acceptable tolerances. The Inspector should ensure that the culvert is installed to dimensions and specifi cati ons in the plan package. This includes proper depths, cover, and fl ow tolerances.


Prior to constructi on, the contractor shall submit the following for approval:

1. Project Schedule that included milestones and dates for the constructi on, traffi c control, concrete placement and backfi ll.

2. Excavati on safety plan.

Page | 21

CHAPTER 6


3. Certi fi cati on of manufactured materials such as reinforcing steel.

4. Concrete Mix designs.

5. Certi fi cati ons for bedding materials and backfi ll materials.

6. Shop drawings for any associated structural steel items such as inlet grates and frames.


Common Issues


1. Excavati on does not meet OSHA safety standards.

2. Materials Certi fi cati ons or mix designs are missing or do not meet specifi cati ons.

3. Reinforcing steel is not properly placed or ti ed.

4. Concrete is not properly placed or fi nished.

5. Concrete material testi ng does not meet specifi cati ons.

6. Bedding material is not adequately compacted or prepared.

7. Backfi ll materials do not meet specifi cati ons or is not adequately compacted.

8. Structure is not properly formed or shored.


10. Structure is not constructed to proper dimensions or tolerances.



Pre-Inspection Project schedule.

Shop drawings and design calculations signed and sealed by Utah licensed professional engineer.

Material certifi cations and mix designs.

Contractor has used a prequalifi ed source for precast structures.

Excavation safety plan.

Reinforcing steel has been properly placed and tied.

Anchor bolts, fence post and incidental items have been installed.

Erection Plan is required prior to placement.

Buy America Documentation if applicable.

Field Documentation Excavation meets safety standards.

Bedding material properly constructed.

Reinforcing steel has been properly placed and tied.

Forming and shoring meet requirements.

Concrete is properly placed and meets materials tests.

Backfi ll materials meet specifi cations and have been properly compacted.

Structure is built to acceptable dimensions and tolerances.


Field Inspection Site is excavated to the required depth and elevation.

Contractor has used suitable materials for backfi ll, depth of lift, optimum moisture and compaction. Refer to Chapter 3 of this guide.

Contractor has provided the test reports from the UDOT Materials Division for precast structures.

Compaction and fi ll requirements have been met. Backfi ll documentation per MS&TR Section 02056.

02646: CONCRETE BOX CULVERTS

Page | 23

CHAPTER 6


C) PRECAST NOISE RETAINING WALLS - SECTION 02861

General

This item includes the materials, fabricati on and placement for precast noise-retaining walls. These wall systems are typically pre-fabricated using reinforced concrete. Other walls systems such as Mechanically Stabilized Earth (MSE) walls are covered in other specifi cati ons. Associated work includes forming, false-work and shoring, placement of concrete, fi nishing, and curing.

Precast retaining-noise walls are commonly used to provide a noise and/or visual barrier between traffi c and surrounding communiti es. They can also be used on limited applicati ons such as precast Post and Panel retaining walls.

Precast retaining-noise walls consist of reinforced concrete posts and panels that are prefabricated and shipped to the project site

for installati on. Fabricati on is typically completed by a pre-approved fabricator and inspected for approval by UDOT’s Central Materials Division prior to shipment. However, walls are also occasionally cast on site with the prior approval by UDOT’s Materials Division.

UDOT’s central materials division is responsible for the quality control of precasti ng process including materials, forming, casti ng and curing of prestressed concrete structural components. As such, the Resident Engineer or staff should noti fy UDOT’s central materials and structures division of contractor schedule to fabricate precast walls systems. The Resident Engineer will receive “shop drawings” submitt ed for approval prior to fabricati on. The Resident Engineer is responsible to forward these drawings to the designer of record and also noti fy UDOT’s central materials and bridge inspecti on staff .

The central materials Inspector will verify the fabricati on process including materials requirements for aggregates, concrete mix designs, reinforcing steel and aggregates. They will also verify the casti ng and curing processes. Once cured and approved, the precast components will be shipped with a label certi fying the quality and approval. The fi eld Inspector should verify this label is present prior to placement on the project site. Once the fi nished product leaves the precast yard, it becomes the responsibility of the fi eld Inspector who is to ensure that the component is handled properly and not damaged. As posts and panels are placed in to fi nal



positi on, the Inspector should verify that the contractors lift ing practi ces are safe and adequate. Once in place, the Inspector should also verify that the contractor has properly braced or shored the component to prevent it from moving or falling.

The Inspector should ensure that the posts and panels are installed to dimensions and specifi cati ons in the plan package. This includes proper depths of post embedment, concrete post grout placement, height, spacing and joint tolerances. Panels should be verti cally plumb, and free of surface defects.

In general, the fabricator is responsible for producing a quality precast product, and the contractor for the proper placement and constructi on of the component. The Inspector is responsible to ensure that processes have been followed for both fabricati on and installati on.


Prior to fabricati on and installati on, the contractor shall submit the following for approvalal:

1. Project Schedule that included milestones and dates for the fabricati on, shipping and placement of precast concrete structural components.

2. Shop Drawings for approval of Precast components by the design Engineer with noti fi cati on to UDOT’s Structures Division.

3. Noti fi cati on to UDOT’s Central Materials Lab and Resident Engineer of schedule to form and cast the precast components.


5. Erecti on Plan.


Page | 25

CHAPTER 6


Common Issues







6. Contractor fails to shore or brace components aft er placement.

7. Post are not imbedded to proper depth or grouted with concrete as specifi ed.

8. Panels are not installed to acceptable dimensions or fi t.

Pre-Inspection Contractor to submit project schedule that includes precast items.





Wall Erection Plan is required prior to placement.

Field Documentation Central Materials to certify fabrication and approval of component.



Ensure components are properly braced after placement.

Ensure proper fi t and construction to acceptable dimension tolerances.


02861: PRECAST RETAINING NOISE WALL



D) OVERHEAD SIGN VMS STRUCTURE - SECTION 02893

General

This item includes specifi cati ons for the materials, fabricati on and installati on of structural steel materials used in the constructi on of overhead sign and VMS signs. Structural steel components are typically used to construct the frame of these structures and reinforced concrete is used to construct the foundati ons. Structural Steel and Reinforced Concrete specifi cati ons should also be used with these structures. Additi onal “Buy America” requirements apply for Federally funded projects.

Poor material or constructi on quality has the potenti al for catastrophic failure of these structures. The Resident Engineer and Inspector are responsible to ensure that the process for producing the materials and fabricati ng the fi nal products follow specifi cati ons. In additi on, they are responsible to ensure that the fabricated products are properly placed and constructed in the fi eld.

Certi fi cati ons

Structural steel is available in common and custom shapes, grades and dimensions from both domesti c and foreign manufacturers. Steel is manufactured by a steel mill (manufacturer) from raw materials into common shapes and sizes. A steel supplier or fabricator typically resells, reshapes or modifi es the steel into the fi nal product shape and confi gurati on. The steel producti on mill and fabricator may or may not be the same company and the Inspector is responsible for certi fi cati ons for both the materials and fabricati on.

Certi fi ed Mill Test Reports (MTR) must be submitt ed for all structural steel materials, including those manufactured outside the United States. Additi onal “Buy America” requirements apply

for Federally funded projects. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certi fi ed if components are used on a bridge structure.


Page | 27

CHAPTER 6


Reinforced concrete foundati ons require the approval of aggregates, mix designs, reinforcing steel and materials testi ng of the concrete.

Drawings

The fabricator and contractor are required to submit detailed shop and erecti on drawings prior to fabricati on and erecti on. Aft er approval, the shop drawings become a part of the project plans and are used in lieu of the general plans insofar as steel details are concerned. During erecti on, make sure all members are placed in their proper positi on in the structure by checking match marks or identi fi cati on marks on the members with the locati on shown on the erecti on drawing. When checking the shop drawing, the goal is to end up with error free drawings. The drawings are checked and approved by the UDOT Structures Division. When the shop drawings are approved they are not guaranteed to be free from error nor are the Fabricator and Contractor relieved from the responsibility to furnish material that meets the requirements of the Plans and Specifi cati ons. Although the shop drawings are checked and approved, be alert to catch fabricati on discrepancies.

Shop Inspecti on

The Contractor will be required to provide at least two week’s noti ce before the beginning of shop work so that shop inspecti ons can be scheduled. Such inspecti on is normally provided by the Central Materials and/or Structures Division. Nevertheless, perform a steel visual inspecti on as it is received on the project, before unloading. The inspecti on requirements for the shop inspecti on are provided in the AASHTO Constructi on Manual of Highway Bridges and Incidental Structures.

Unloading, Handling and Storing Upon delivery of the steel it is inspected for signs of damage and any such damage is documented and reported to the Contractor. The unloading of the steel is accomplished by means of equipment and methods which will not damage the members. The steel is moved by use of slings and wood blocks to prevent damage to the fl anges. Steel members are never to be dropped. Steel is stored in a well-drained area which is not in danger of being fl ooded. All beams and girders are placed in an upright positi on, on wooden blocks. Blocking is provided that will keep all members off the ground and clear of grass, brush or other material. Long members are supported in a manner that will prevent damage from defl ecti on. The members are also handled and transported in an upright positi on. They are braced to prevent overturning. A girder erecti on plan stamped by a licensed Structural Engineer is required from the contractor and supplier prior to installing steel girders.



Erecti on and Constructi on

The structural steel components are to be erected and placed into fi nal positi on by an experienced contractor. The Inspector should ensure that girders and other components properly fi t and are placed into the positi on as shown on the plans. Field cutti ng, welding and bending during erecti on should not be allowed without the approval of the Designer or a Structural Engineer due to the potenti al to weaken the capacity of the structure. Placement oft en occurs over several days, and the Inspector should ensure that the contractor has taken precauti on to brace and restrain the components from moving or falling.



1. Project Schedule with milestones for fabricati on.

2. Certi fi cati ons of nut proof load tests.

3. Buy America certi fi cati on (if applicable)


5. Fabricator certi fi cati on as AISC-CBR if a bridge structure.

6. Shop Drawings.

7. Erecti on Plans for bridges stamped by a Structural Engineer.

Common Issues

The Inspector and Resident Engineer are responsible to document common contractor errors and noti fy a Structural Engineer if any of the following are observed:

1. Shop Drawings are delayed or missing or not stamped by a Structural Engineer.

2. Missing approvals, certi fi cati ons, and inspecti ons that have not been coordinated with Central Materials or Structures Divisions.

3. Damage of steel during shipment or placement.

4. Improper welding, cutti ng, bending or modifi cati on in fi eld


6. Excessive defl ecti on, movement or instability.

7. Non approved connecti on hardware.

8. Bolts under-ti ghtened or over-ti ghtened at splice plates or diaphragms.

Page | 29

CHAPTER 6


E) REINFORCING STEEL AND WELDED WIRE FABRIC - SECTION 03211

General

This item includes the material and placement for reinforcing steel and welded wire fabric used in reinforced concrete structures. In general, reinforcing steel or welded wire fabric shall

conform to the proper grade, size, and dimensions as specifi ed in the plan package. The materials must meet certi fi cati on requirements. Most reinforcing steel used on highway projects is coated with epoxy or galvanized to prevent corrosion. The Inspector should ensure that the contractor has placed the reinforcing steel and welded wire fabric to the proper locati on, dimensions and geometry as specifi ed in the plan package, including cover, spice lengths and securing with ti e wire and support chairs. Buy America requirements apply to Federally funded projects.

Pre-Inspection Contractor to Submit Project Schedule including structural steel items.


Contractor to submit Nut proof load tests.

Contractor/Supplier to submit Mill Certifi cations.

Contractor/Suppler to submit AISC-CBR certifi cations if a bridge.

Contractor to submit erection plan for bridges stamped by SE.

Field Documentation & Inspection Central Materials to certify and approve fabrication.






Ensure all bolts have been adequately tightened.

02893: OVERHEAD SIGN VMS STRUCTURES




Prior to installati on, the contractor shall submit the following for approval:

1. Material Certi fi cati ons for reinforcing steel and welded wire fabric.

2. Shipping invoices with manufacturer contact informati on, lot numbers, rebar bar call outs, size, and quanti ti es.

3. Plan for storage of materials prior to placement.

Common Issues


1. Material lacks proper certi fi cati ons and documentati on. Material damaged or not stored properly.

2. Material improperly placed and does not meet plans or specifi cati ons. Protecti ve coati ng is damagŜd.

Pre-Inspection Submit material certifi cations and source of manufacturing. Submit shipping invoices. Buy America documentation if applicable.

Field Documentation Observe that reinforcing materials have proper fi eld tags to identify. Observe that reinforcing materials are properly stored. Ensure that protective coatings are not damaged. Observe that reinforcing materials have been properly placed to the proper location including tensile and compressive faces.

Ensure that reinforcing materials have proper cover. Ensure that reinforcing materials have proper splice length. Ensure that reinforcing steel is properly tied and secured so as not to move or displace during concrete placement. Ensure that exposed reinforcing ends are covered and do not create a safety hazard. Maintain documentation for reinforcing materials including certifi cations, shipping invoices and approval notices.

03211: REINFORCING STEEL AND WELDED WIRE FABRIC

Page | 31

CHAPTER 6


F) STRUCTURAL CONCRETE - SECTION 03310

General

This item includes the material and placement for structural concrete for cast in place applicati ons. Associated work includes forming, false-work and shoring, placement of concrete, fi nishing, and curing.

In general, the contractor shall provide a mix design that meets the specifi c requirements of the structure plans and place the concrete in a manner that provides the desired strength, fi nish and quality.

The Inspector is responsible to ensure that the material and placement are sati sfactory and documenti ng the process. Prior to placement of structural concrete, the Inspector shall inspect the reinforcing steel, forming and mix designs and give a noti ce to proceed for concrete placement.

During placement, the Inspector shall perform material tests or coordinate with the materials testi ng personnel for items such as air entrainment, slump and compressive strength. The Inspector is also responsible to ensure that workmanship meets the plan package including the use of equipment such as concrete pumps and vibrators and fi nishing of exposed surfaces.



1. Concrete Mix Design for approval by the Engineer.

2. Prior noti fi cati on of schedule to place concrete and noti fi cati on to Inspectors and materials testi ng personnel.

3. The Engineer must give approval and noti ce to proceed with concrete placement prior to performing work.



Common Issues


1. Concrete materials do not have approved mix design.

2. Reinforcing steel is not properly placed.

3. Forming and shoring are not properly placed.

4. Improper use of equipment such as concrete pumps, tremmies and vibrators.

5. Substandard workmanship and fi nishing.

6. Concrete does not meet air, slump or strength requirements.

7. Concrete does not meet mix ti mes or haul ti me requirements.

8. Excessive cold, heat or weather conditi ons.

9. Segregati on of aggregate from mix during placement.

10. Finished grade aff ected by dead load defl ecti ons of concrete weight.

Pre-Inspection Contractor to Submit concrete mix design for approval.

Contractor to give prior notice of schedule for inspection & material testing.

Inspector to ensure forming and shoring in place.

Inspector to ensure reinforcement in proper placement.

Ensure that contractor has compensated for dead load defl ections.

Contractor has adequate equipment (tremmies, pumps, etc.).

Ensure that anchor bolts, fence posts and other details are in place.

Field Documentation Ensure concrete meets air entrainment and slump requirements.

Ensure that pumping equipment is properly used and from an approved source.

Ensure that workmanship meets requirements of plan package.

Ensure that reinforcing steel does not move during placement.

Maintain documentation for reinforcing materials including certifi cations, shipping invoices and approval notices.

Document location and time of placement and construction joints.

03310: STRUCTURAL CONCRETE

Page | 33

CHAPTER 6


G) CONCRETE CURING - SECTION 03390

General

This item includes the specifi cati ons for the curing of concrete. Requirements specifi c to concrete structures are included within this specifi cati on.

In general, the majority of structural concrete is performed on the job site using cast constructi on methods. Concrete cures in part by a chemical reacti on where the cement ingredients react with the hydrogen molecules that are present in the water. If the water is allowed to excessively evaporate, the concrete quality can be reduced.

As a result, concrete curing compounds are used to seal the moisture in during the curing process for all cast in place concrete structures. Bridge decks and approach slabs require the additi onal use of a fabric or other material that retains moisture. Unless specifi ed otherwise, curing compounds are to be applied within 20 minutes of placement of the concrete at an applicati on rate not to exceed 100ft /gallon.

In some cases, precast concrete may be used and have specifi c requirements for curing such as early strength, or controlled environment conditi ons such as wet curing, steam curing, and temperature controls. The quality inspecti on for precast structural components is typically performed by UDOT’s Central Materials Division. The fi eld Inspector is responsible to noti fy the Central Materials Division of upcoming precast elements for their project.

Curing Compounds and curing fabrics are available from numerous suppliers and manufacturers. The contractor is responsible to provide the Engineer with a process to ensure



that moisture levels are maintained during the curing of structural concrete. The contractor is responsible to select appropriate materials that meet UDOT specifi cati ons. The contractor must submit material informati on including the manufacturer, material certi fi cati ons, product data, specifi cati ons, and recommended instructi ons.

The Resident Engineer and fi eld Inspector are responsible to approve material submitt al prior to use. In additi on, they need to observe that curing compounds are adequately applied in a ti mely manner.


Prior to use, the contractor shall submit the following for approval:

1. Curing Compound

a. Material Supplier Informati on

b. Product Data

c. Material Certi fi cati on

d. MSDS sheets

2. Curing Fabric (decks)

a. Material Supplier Informati on

b. Product Data

c. Material Certi fi cati on

Common Issues


1. Material Certi fi cati ons are missing.

2. Missing product installati on instructi ons.

3. Applicati on rates are not maintained.

4. Improper storage of materials.

5. Wet conditi ons are not maintained for curing fabrics.

6. Cold Weather Concrete.

Page | 35

CHAPTER 6


H) PENETRATING CONCRETE SEALER - SECTION 03392General

This item includes materials used as a preventi ve treatment to seal water and deicing salts from structural concrete surfaces. The contractor is responsible to provide acceptable materials and apply them in a manner that meets specifi cati ons for the project. The Inspector is responsible to verify material certi fi cati ons, observe acceptable applicati on and document the process.



1. Manufacturer’s product data, material certi fi cati ons, recommendati ons for storage and installati on.

2. Certi fi cati ons of minimum fricti on numbers when used on traveled surfaces.

Common Issues


1. Missing product data and installati on instructi ons.

2. Improper storage or handling.

3. Applicati on rates do not meet specifi cati ons.

4. Overspray during applicati on.

5. Storage and handling.

Pre-Inspection Contractor to Submit manufactures contact information, product data, material certifi cations, MSDS Sheets, storage requirements, and installation instructions for curing compounds and fabrics.

Central Materials Division has been notifi ed of any precast elements on the project.

Field Documentation Verifi cation and documentation of material certifi cations.

Inspector to document and verify storage and installation.

Ensure components are properly placed and maintained during cure.


03390: CONCRETE CURING



I) PRESTRESSED CONCRETE - SECTION 03412

General

This item includes the materials and placement for structural concrete that includes the use of pre-stressing strands (wire cables) which are used to add strength and load capacity for the structural secti on. Associated work includes forming, false-work and shoring, placement of concrete, fi nishing, and curing.

Prestressing strands are commonly used for concrete bridge girders, and occasionally used for other structural members such as precast deck panels or pier caps. Prestressed concrete is almost always completed by a UDOT approved precast concrete fabricator. The process involves the tensioning (prestressing) of the strands (wire cables) before the concrete is placed. Once the concrete has been placed and cured to a sati sfactory strength, the strand ends are cut.

Pre-Inspection Contractor to submit manufacturer’s product data, material certifi cations, specifi cations and instructions for use and storage.

Manufacturer and Contractor to submit Materials Safety Data Sheets (MSDS) with instructions for handling, safety and emergencies.

Inspector to coordinate approvals with UDOT Central Materials Division.

Ensure documentation of material submittals.

Field Documentation Inspector to document and verify materials certifi cation.

Ensure components are properly stored.

Materials are safely and properly mixed.

Materials are applied at specifi ed coverage.

Proper disposal of waste materials.

Documentation of certifi cations, and application in inspection diaries.

03392: PENETRATING CONCRETE SEALER

Page | 37

CHAPTER 6


UDOT’s central materials division is responsible for the quality control of the precasti ng process including materials, forming, casti ng and curing of prestressed concrete structural components. As such, the resident Engineer or staff should noti fy UDOT’s central materials and structures division of contractor schedule to fabricate prestressed elements. The Resident Engineer will receive “shop drawings” submitt ed for approval prior to fabricati on. The Resident Engineer is responsible to forward these drawings to the designer of record and also noti fy UDOT’s central materials and bridge inspecti on staff .

The central materials Inspector will verify the fabricati on process including materials requirements for aggregates, concrete mix designs, reinforcing steel and prestressing strands. They will also verify the casti ng and curing processes. Once cured and approved, the precast components will be shipped with a label certi fying the quality and approval. The fi eld Inspector should verify this label is present prior to placement on the project site. Once the fi nished product leaves the precast yard, it becomes the responsibility of the fi eld Inspector who is to ensure that the component is handled properly and not damaged. As girders or other component are placed in to fi nal positi on, the Inspector should verify that the contractors lift ing practi ces are safe and adequate. Once placed, the Inspector should also verify that the contractor has properly braced or shored the component to prevent it from moving or falling.



The design of prestressed structural components takes into account added weights from dead loads such as decking and parapets. If a girder or other component is allowed to be stored for too long of a ti me before placement of these dead loads, there is a potenti al for the component to “bow” or lose shape. The Inspector should ensure that the girders are installed in a reasonable period of ti me aft er fabricati on.

Prestressed girders typically are installed in the fi eld with bracing (diaphragms) between the girders to provide lateral stability. The Inspector should ensure that all diaphragms have been properly installed or constructed before opening to traffi c. Diaphragms can be constructed in the fi eld using reinforced cast-in-place concrete or installati on of prefabricated steel diaphragms. The Inspector needs to ensure that reinforcing steel and concrete is properly installed. Proper installati on of connecti on bolts and welding of steel diaphragms needs to be verifi ed in the fi eld.

In general, the fabricator is responsible for producing a quality precast product, and the contractor for the proper placement and constructi on of the component. The Inspector is responsible to ensure that processes have been followed for both fabricati on and installati on.



1. Project Schedule that included milestones and dates for the fabricati on, shipping and placement of prestressed concrete structural components.

2. Shop Drawings for approval of Prestressed and Precast components by the design Engineer with noti fi cati on to UDOT’s Structures Division.

3. Noti fi cati on to UDOT’s Central Materials Lab and Resident Engineer of schedule to form and cast the prestressed components.


5. Erecti on Plan stamped by a Professional Structural Engineer for bridge projects.

Page | 39

CHAPTER 6


Common Issues







6. Contractor fails to shore or brace components aft er placement.

7. Finished product is stored too long before adding deck or other dead loads resulti ng in excessive camber.

8. Damage during shipment or placement.

Pre-Inspection Contractor to submit project schedule that includes prestressed items.





Girder Erection Plan stamped by a Structural Engineer is required prior to placement of girders.






03412: PRESTRESSED CONCRETE



J) STRUCTURAL STEEL - SECTION 05120

General

This item includes specifi cati ons for the materials, fabricati on and installati on of structural steel materials used in the constructi on of bridges and other transportati on structures. Common structural steel components include; steel girders, sign structures, girder diaphragms, and connecti on bolts and hardware. Associated items include nuts, bolts, washers and other miscellaneous components. Additi onal “Buy America” requirements apply for Federally funded projects.

Steel components used on structures typically are designed to carry loads and support the weight of the bridge and traffi c. Poor material or constructi on quality has the potenti al for catastrophic failure of the structure and loss of life. The Resident Engineer and Inspector are responsible to ensure that the process for producing the materials and fabricati ng the fi nal products follow specifi cati ons. In additi on, they are responsible to ensure that the fabricated products are properly placed and constructed in the fi eld.

Certi fi cati ons

Structural steel is available in common and custom shapes, grades and dimensions from both domesti c and foreign manufacturers. Steel is manufactured by a steel mill (manufacturer) from raw materials into common shapes and sizes. A steel supplier or fabricator typically resells, reshapes or modifi es the steel into the fi nal product shape and confi gurati on. The steel producti on mill and fabricator may or may not be the same company and the Inspector is responsible for certi fi cati ons for both the materials and fabricati on.

Certi fi ed Mill Test Reports (MTR) must be submitt ed for all structural steel materials, including those manufactured

Page | 41

CHAPTER 6


outside the United States. Additi onal “Buy America” requirements also apply for Federally funded projects. The fabricator of structural items must be AISC – Major Steel Bridge (CBR) certi fi ed if components are used on a bridge structure.


Drawings

The fabricator and contractor are required to submit detailed shop and erecti on drawings prior to fabricati on and erecti on. Aft er approval, the shop drawings become a part of the project plans and are used in lieu of the general plans insofar as steel details are concerned. During erecti on, make sure all members are placed in their proper positi on in the structure by checking match marks or identi fi cati on marks on the members with the locati on shown on the erecti on drawing. When checking the shop drawing, the goal is to end up with error free drawings. The drawings are checked and approved by the UDOT Structures Division. When the shop drawings are approved they are not guaranteed to be free from error nor are the Fabricator and Contractor relieved from the responsibility to furnish material that meets the requirements of the Plans and Specifi cati ons. Although the shop drawings are checked and approved, be alert to catch fabricati on discrepancies.

Shop Inspecti on

Advise the Contractor that it will be necessary to have at least two week’s noti ce before the beginning of shop work so that shop inspecti ons can be scheduled. Such inspecti on is normally provided by the Central Materials and/or Structures Division. Provide a visual inspecti on as it is received on the project, before unloading. The inspecti on requirements for the shop inspecti on are provided in the AASHTO Constructi on Manual of Highway Bridges and Incidental Structures.

Unloading, Handling and Storing Upon delivery of the steel it is inspected for signs of damage and any such damage is documented and reported to the Contractor. The unloading of the steel is accomplished by means of equipment and methods which will not damage the members. The steel is moved by use of slings and wood blocks to prevent damage to the fl anges. Steel members are never to be dropped. Steel is stored in a well drained area which is not in danger of being fl ooded. All beams and girders are placed in an upright positi on, on wooden blocks. Blocking is provided that will keep all members off the ground and clear of grass, brush or other



material. Long members are supported in a manner that will prevent injury from defl ecti on. The members are also handled and transported in an upright positi on. They are braced to prevent overturning. A girder erecti on plan stamped by a licensed Structural Engineer is required from the contractor and supplier prior to installing steel girders.

Erecti on and Constructi on

The structural steel components are to be erected and placed into fi nal positi on by an experienced contractor. The Inspector should ensure that girders and other components properly fi t and are placed into the positi on as shown on the plans. Field cutti ng, welding and bending during erecti on should not be allowed without the approval of the designer or a Structural Engineer due to the potenti al to weaken the capacity of the structure. Placement oft en occurs over several days, and the Inspector should ensure that the contractor has taken precauti on to brace and restrain the components from moving or falling.



1. Project Schedule with milestones for fabricati on.

2. Certi fi cati ons of nut proof load tests.

3. Buy America certi fi cati on (if applicable).


5. Fabricator certi fi cati on as AISC-CBR if a bridge structure.

6. Shop Drawings.

7. Erecti on Plans for bridges stamped by a Structural Engineer.

Common Issues

The Inspector and Resident Engineer are responsible to document common contractor errors and noti fy a Structural Engineer if any of the following are observed:

1. Shop Drawings are delayed or missing or not stamped by a Structural Engineer.

2. Missing approvals, certi fi cati ons, and inspecti ons that have not been coordinated with Central Materials or Structures Divisions.

3. Damage of steel during shipment or placement.

Page | 43

CHAPTER 6


4. Improper welding, cutti ng, bending or modifi cati on in fi eld


6. Excessive defl ecti on, movement or instability.

7. Non-approved connecti on hardware.

8. Bolts under-ti ghtened or over-ti ghtened at splice plates or diaphragms.

K) BEARINGS - SECTION 05822

General

This item includes the materials and placement for bearings used in conjuncti on with bridge girders. Bearings are required to help distribute the weight of the beams and traffi c to the bridge foundati on. Before erecti on of girders is started, the centerline of bearings is laid out on abutments and pedestals. Bearing areas are inspected to ensure that a smooth surface is provided at the correct elevati on. If the concrete surface that will be in contact with the bearing pad is rough or irregular, it is ground to provide full and uniform bearing. If a bearing area is low with respect to other areas on the unit or in relati on other units of the structure, shims of the same size as the masonry plate, and of the required thickness, are ordered with the approval of

Pre-Inspection Contractor to Submit Project Schedule including structural steel items.


Contractor to submit Nut proof load tests.

Contractor/Supplier to submit Mill Certifi cations.

Contractor/Suppler to submit AISC-CBR certifi cations if a bridge.

Contractor to submit erection plan for bridges stamped by SE.

Field Documentation & Inspection Central Materials to certify and approve fabrication.






Ensure all bolts have been adequately tightened.

05120: STRUCTURAL STEEL



the Structures Division. The most common bearing materials are preformed elastomeric pads or steel. Buy America requirements apply to Federally funded projects.

Bearing Pads

Pre-formed fabric or plasti c bearing pads are required to conform to AASHTO Specifi cati on M-108 for Highway Bridges. Such pads may be used without testi ng provided a certi fi cati on has been received stati ng that the material proposed for use complies with the Specifi cati ons. If no certi fi cate has been received, a sample is submitt ed and tested by the Materials Division before use. Steel bearing units must meet structural steel specifi cati ons and require material certi fi cati ons.

Installati on

Bearing surfaces need to be free of debris. Contact surfaces of beams need to be free of paint or lacquer. Elastomeric bearing pads are placed under the girders to dimensions shown in the plans. Care should be taken as girders are set as to not tear or damage the bearing pads. Styrofoam is placed in front of the bearing pads for abutments that will have cast in place end diaphragms.

Steel bearing systems oft en include anchor plates and connecti on bolts. Care should be taken to ensure that anchor bolts are properly installed in the correct locati on prior to setti ng girders. Welding or cutti ng of any structural steel should not be allowed unless specifi ed on the plans or

Page | 45

CHAPTER 6


approved by a Structural Engineer. Older style rocker bearing units require “setti ng” the angle to the ambient temperature when installed.



1. Shop Drawings for approval per secti on 05120.

Common Issues


1. Shop Drawings are delayed.

2. Approvals, certi fi cati ons, and inspecti on not coordinated with Central Materials.

3. Finish of abutment concrete is substandard.

L) PAINTING STRUCTURAL STEEL - SECTION 09972General

This item includes specifi cati ons for the materials and applicati on of painti ng systems for structural steel. Structural steel painti ng is performed primarily to extend the life of a structure by slowing the corrosion process. This specifi cati on is for new painti ng systems. Requirements for top-coati ng or repainti ng of structural steel are covered in other specifi cati ons.

The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these

Pre-Inspection Contractor to Submit Shop Drawings for approval.

Inspector to coordinate inspection with UDOT Central Materials and Structures Division.

Inspector to ensure proper placement.





05822: BEARINGS



two conditi ons are met. In additi on, the Inspector needs to ensure that the paint systems do not adversely aff ect the environment, or worker safety.

Paint Systems

Painti ng of structural steel does not use a single paint with several coats, but rather a “paint system” that includes proper surface preparati on, several coats of diff erent materials, and applicati on procedures. UDOT follows general requirements established by the Northeast Protecti ve Coati ngs Committ ee (NEPCOAT). A 3-part coati ng system is required consisti ng of a zinc primer, epoxy or urethane intermediate coat, and aliphati c urethane top coat. Diff erent colors are required for each coat to assist in visual inspecti on of the coverage.

Painti ng Plan

The contractor is required to submit for approval a comprehensive painti ng quality plan that includes the following:

• Painti ng Protecti on plan that includes environmental protecti on plans, and overspray protecti on plans.

• Safety Plan for worker exposure and fall protecti on.

• Source, gradati on and procedures for sandblasti ng and surface preparati on. Type and source of solvents and thinning agents.

• Material informati on and data for each component of the 3 part paint system. This shall include fi lm thickness requirements, Product Safety Data, thinning requirements, temperature requirements, surface profi le (roughness) requirements, mixing instructi ons and equipment recommendati ons.

Materials AcceptanceIn additi on to the requirements of the painti ng quality plan, the contractor and material suppliers are required to submit certi fi cati ons and samples of paint systems for testi ng, review

Page | 47

CHAPTER 6


and approval to UDOT’s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to the standard.

Painter and Sandblaster Qualifi cati onsThe painter and sandblaster are required to be certi fi ed prior to the contract award by the Society of Protecti ve Coati ngs (SSPC). Diff erent certi fi cati ons are required for painters and sandblasters and for fi eld work and shop work.

Constructi on Inspecti onThe Inspector is responsible to verify the painti ng process including surface preparati on, mixing and blending of paints, applicati on of paint

system, safety, equipment and environmental impacts. The Inspector shall verify the surface are clean and have a surface profi le that will allow paint to adequately bond to the steel surface. The Inspector will also verify applicati on rates, mill thicknesses, uniformity and quality of the applied paint.

Submitt al RequirementsThe contractor shall submit the following for approval:

1. Project Schedule with milestones for painti ng operati ons.

2. Paint Plan including: Environmental protecti on plan, safety plan, materials source and data, sandblasti ng operati ons, test samples and a quality plan.

3. Approval of paint samples by UDOT Central Materials.

4. Certi fi cati on of Painters and Sandblasters.

Common Issues

Common issues that the Inspector and Resident Engineer may encounter include:

1. Contractor does not submit all requirements of the painti ng plan.

2. Paint or sandblasti ng materials do not meet standards or tests.

3. Contractor does not adequately protect workers from paint and sandblasti ng hazards.



4. Contractor does not adequately protect surrounding environment or traffi c from overspray.

5. Surface is not adequately cleaned or does not have an eff ecti ve surface profi le for the paint system to bond to.

6. Paint is applied at improper applicati on rates, thicknesses or lacks uniformity.

7. Too much ti me between prime, intermediate and top coats.

Pre-Inspection Submittal of Painting Plan including requirements of 09972.

Painter and Sandblaster qualifi cations.

Material Safety Data Sheets.

Test samples submitted to Central Materials Paint lab.

Field Documentation & Inspection Field pre-qualify painters using test area.

Verify enforcement of safety plan, including scaffolding, fall protection and work exposure to hazardous materials.

Ensure paint and other materials are properly shipped and stored.

Ensure MSDS sheets and product information is readily available.

Ensure surfaces are clean and prepared to acceptable profi le and free of debris and dust prior to paint coat.

Measure application rates, thicknesses and processes for applying paint.

09972: PAINTING STRUCTURAL STEEL

Page | 49

CHAPTER 6


6.5 BRIDGE DECKS, APPROACHES AND JOINTS

A) BRIDGE CONCRETE GRINDING - SECTION 02982

General

This item includes procedures for grinding new concrete deck and approach slab systems. Grinding of the concrete deck and approach slab surfaces is typically done to achieve a desired profi le and ride of precast concrete bridge deck systems. Grinding is also performed to remove polymer overlay systems, or to remove deteriorated concrete.

The Inspector should visually inspect the equipment and operati ons to ensure that the grinding operati ons do not cause damage to reinforcing steel, steel grati ng or expansion joints. Grinding operati ons oft en can create dust, noise, and waste water which have potenti al for safety hazards to workers and drivers. The Inspector should also inspect the overall safety of the operati ons and ensure that the contractor has obtained necessary permits.


Prior to constructi on, the contractor shall submit the following for approval:

1. Noise and other related permits.

Common Issues


1. Equipment breakdowns.

2. Damage to reinforcement, joints and grati ng.

3. Cross slope drainage not achieved.

4. Grinding surface not longitudinal and smooth.

5. Missing noise permits.



B) JOINT CLOSURE - SECTION 03311General

Prior to the 1980’s the bridge deck joints were used more frequently than current design practi ces. Bridge deck joints typically leak allowing water and deicing salts to drain onto the piers and columns below increasing the rate of deteriorati on for the bridge. As a result, bridge deck joints are eliminated (closed) where possible on existi ng bridges.

Inspecti on

A bridge deck joint closure consists of removing the existi ng joint system, installing reinforcing steel and casti ng concrete to fi ll the joint area (closure). This specifi cati on describes materials and processes for removing and closing deck joint systems. Custom plans are typically prepared that are specifi c to the individual bridge. The Inspector should take extra eff ort to understand the bridge plans and ask for clarifi cati on from the designer if needed.

The Inspector should ensure that the removal operati ons do not cause damage to the surrounding concrete and structure. Jack hammers and other equipment should be an appropriate size as to not cause damage. Placement of new reinforcing is typically doweled spliced or mechanically coupled to the adjacent deck reinforcement. The Inspector should verify that the placement of

Pre-Inspection Verify equipment meets the job size and complexity. Discuss common issues with contractor prior to grinding operations. Allow cure time for cast in place deck joints. Defi ne smoothness requirements with contractor before grinding. Obtain necessary noise and waste water permits.

Field Documentation Inspect and Verify smoothness. Inspect and Verify drainage. Ensure vacuuming or collection of waste water. Inspect and verify grinding depth. Inspect and verify that no damage has occurred to deck joints, catch basins or surface.

Document labor and equipment used.

02982: BRIDGE CONCRETE GRINDING

Page | 51

CHAPTER 6


reinforcing steel matches what is specifi ed in the plans. Material certi fi cati ons are required for the reinforcing steel and mix designs for the concrete.

Submitt al Requirements1. Prior to removal and closure, the contractor

shall submit the following for approval:

2. Removal Plan with list of jack hammers and other equipment to be used. Material Certi fi cati ons for reinforcing steel.

3. Mix designs for concrete.

Common Issues

The Inspector should watch for these common issues:

1. Removal process damages surrounding concrete. Sawcutti ng is too deep, jackhammers are too heavy, etc.

2. Material certi fi cati ons are delayed, or concrete mix designs are not approved.

3. Deteriorati on to surrounding concrete is more than expected.

4. Ride of fi nished concrete is not smooth.

Pre-Inspection Approved equipment for removal of existing joint system.

Approved Concrete Mix Design.

Certifi cations for materials including reinforcing steel.

Buy America documentation if applicable.

Field Documentation Saw-cut to proper depth.

Jack hammering and removal process does not damage surrounding concrete or structure.

New reinforcing steel is properly placed and protective coatings are touched up if damaged.

Concrete is properly formed, placed and cured.

Document temperature and placement for closure operations.

Field test concrete for air entrainment and slump.

03311: JOINT CLOSURE



C) PRECAST CONCRETE DECK PANELS - SECTION 03339

General

Historically, most bridge decks were constructed with cast in place concrete. However, in recent years the use of precast concrete deck panels has dramati cally increased. Precast deck panels are commonly used to accelerate constructi on schedules, are used where ready mix materials are not available, or where the design wants a higher level of control in the curing process.

Precast deck panels are used on both new constructi on and deck replacement projects. They off er tremendous benefi ts such as a higher level of quality control during fabricati on, winter weather constructi on, remote constructi on and rapid constructi on. However, they also pose additi onal complexiti es such as lift ing, and fi t of the panels. Precast deck panels are also commonly post tensioned with wire cables aft er placement to secure and ti e the panels together.

A primary role of the Inspector for precast deck panels is the coordinati on and communicati on of the fabricati on and constructi on processes with other groups. Precast deck panels are a specialty structural item, and the Inspector needs to coordinate the fabricati on, constructi on, inspecti on and approval of these systems with the designer, UDOT’s Structures Division, and UDOT Central Materials Division prior to beginning fabricati on or constructi on.

Page | 53

CHAPTER 6



Prior to fabricati on, the contractor shall submit the following for approval:

1. Project Schedule with details for precast deck panels.

2. Shop Drawings from the precast fabricator for approval.

3. Constructi on Methods Plan.

4. Erecti on Plan.

5. Materials Certi fi cati ons, including grout materials.

Common Issues


1. Certi fi cati ons and Submitt als not on ti me.

2. Lack of noti fi cati on to UDOT Structures and Materials

3. Inadequate Survey and Fit of Panels.

4. Grouti ng of camber strip and block outs.

Pre-Inspection Contractor to Submit Schedule with details for deck panel fabrication and construction.

Notifi cation to UDOT Structures and Materials Divisions.

Shop drawings submitted for approval.

Inspector to verify fabrication has been approved by UDOT Materials and Structures prior to shipment or construction.

Ensure Construction Methods Plan has been submitted and approved.

Ensure Construction Erection Plan has been submitted and approved.

Material Certifi cations have been submitted and approved.

Hold pre-construction -erection meeting.

Field Documentation Inspect and document deck removal process (if required) to ensure no damage to girders and other structural components.

Inspect and document installation of panels including fi t, time, labor and equipment used. Ensure panels are safety handled and lifted into place within tolerances.

Ensure post-tensioning (if required) meets plans and specifi cations.

Ensure grouting of camber strip and anchor block outs have been properly grouted.

03339: PRECAST CONCRETE DECK PANELS



D) THIN BONDED CONCRETE OVERLAY - SECTION 03372General

This item includes procedures for overlaying concrete bridge decks with a thin polymer material and wearing surface aggregate. Thin bonded overlays are typically placed as a preventi ve treatment to seal water and deicing salts from the deck. They are also occasionally placed to improve safety by increasing fricti on values.

Inspecti on

Thin bonded overlays must be applied to a clean, dry deck surface. Without this criti cal step, the polymers are suscepti ble to de-bonding from the deck surface. The fi rst step of the polymer overlay system is to clean the deck using a steel shot blasti ng. Steel shot is used because it does not leave a dust fi lm behind. The steel shot is collected using magnets and recycled. Sand blasti ng is allowed only in areas where steel shot equipment can’t reach such as along the parapets. The Inspector should visually inspect the shot blasti ng operati on including the equipment used to make sure the surface has been properly cleaned of any residues, sealing components, greases, oils, etc. Any potholes or defects in the deck surface should be repaired prior to the shot blasti ng operati on.

Once clean, the polymer resins can be mixed and applied. Polymer overlays come in two components that are liquids. The components are mixed by proporti ons specifi ed by the manufacturer. Once blended, a chemical reacti on starts, and the resin typically will start to gel within 15 minutes or less. It is criti cal to apply the mixed resin quickly to the deck surface before it starts to harden. Also, these polymers generate heat. The mixed resins should not be left to harden in a container as they pose a risk of explosion and injury if the heat can’t escape. The mixed resins should be applied to the deck surface within 5 minutes or less of mixing. The Inspector should visually inspect the blending, mixing and applicati on of the resins. Considerati on should be given to mixing proporti ons, mixing equipment, mix ti mes, and ti me to applicati on.

Once the resins have been applied to the deck surface, they are covered with an aggregate wearing surface. The aggregate is typically basalt or other high wear rock material. The aggregate is spread (broadcast) into the wet resins before they harden.

Page | 55

CHAPTER 6


The Inspector should ensure that the aggregates adequately cover the wet resins before it hardens. Typically, two coats of resin and aggregate are applied. Excess aggregates are swept off before the deck is open to traffi c.


The following items are required for submitt al:

1. Manufacturer’s product data

2. Recommended installati on instructi ons.

Common Issues

The following are common issues with thin bonded polymer overlays:

1. Existi ng deck defects are not properly repaired.

2. Shot blasti ng equipment breaks down.

3. Deck surface is not adequately cleaned, especially of curing compounds on new decks.

4. The deck surface is not dry.

5. Resins are improperly mixed by proporti on or quickly dispersed.

6. Aggregates do not adequately cover the resin before it hardens.

7. Contractor does not clean up excess aggregates.

Pre-Inspection Verify equipment meets the job size and complexity.

Discuss common issues with contractor prior to mixing and application.

Verify deck surface is clean and dry.

Verify material lot numbers and data.

Field Documentation Inspect and verify shot blasting operations.

Inspect and Verify deck is clean and dry.

Inspect and verify resins are properly mixed and blended.

Inspect and verify resins are applied to deck within time limits.

Inspect and verify that aggregates are applied uniformly and excess material is cleaned from deck surface.


03372: THIN BONDED CONCRETE OVERLAY



E) EXPANSION JOINT - SECTION 05832

General

This item includes the materials and placement for expansion joints and associated forming, false work, shoring, and concrete headers.

Most bridges have joints that are designed and constructed to allow for the bridge to defl ect and rotate under traffi c and to expand or contract with changes in temperature. For smaller bridges under approximately 250 feet or less, “relief joints” are used. For larger bridges (greater than 250) expansion joints are used. Buy American requirements apply for Federally funded projects.

Terminology

Expansion joints are available in a variety of confi gurati ons.

A relief joint is typically a small (appoximately 1/2”) verti cal plane that is formed or cut at the end of the deck and approach slab and fi lled with tar or asphalti c fi ller to allow for longitudinal movement and rotati on. Relief joints are used for smaller bridges and are similar to concrete paving joints. Specifi cati ons for relief joints are covered in specifi cati on 07922 and other specifi cati ons.

Simple Expansion Joints are typically used where the movement is between 1-4 inches. The most common system is a Strip Seal Expansion Joint and uses two preformed steel channels that have a neoprene gland that is inserted between the steel rails to allow for expansion. An alternate and less common simple expansion joint is a Rigid Plasti c Foam Expansion Joint which includes a preformed (polystyrene) material that is inserted between the two concrete surfaces to allow for expansion. Strip seal and polystyrene joint systems are included in this specifi cati on.

Structural joints that require several glands or more complex mechanical mechanisms are categorized as Modular Expansion Joints. Modular joints are covered in other specifi cati ons.

Page | 57

CHAPTER 6


Simple expansion joints are manufactured products. Rigid Plasti c Foam systems require material certi fi cati ons. Strip Seal Expansion Joints require material certi fi cati ons and shop drawings. The Inspector and Resident Engineer are responsible to forward shop drawings to UDOT’s Structures Division for review and approval. In additi on, they are responsible to ensure that the joint systems are properly installed.



1. Material certi fi cati ons for rigid plasti c foam expansion joint systems if used.

2. Material certi fi cati ons for neoprene glands and structural steel if strip seal expansion joint systems are used.

3. Shop Drawings for approval if strip seal expansion joint systems are used.

4. Concrete mix designs if concrete headers are used separate of the deck concrete.

Common Issues

Document and noti fy a Structural Engineer if these common issues are identi fi ed:

1. Shop Drawings are delayed or missing.


3. Gland systems are damaged.

4. Poor fi t.

Pre-Inspection Submit Shop Drawings for approval as per specifi cation 05120.

Submit Material certifi cations.

Buy America documentation if applicable.

Field Inspection & Documentation Proper fi t. Will not affect expansion, ride or plowing operations.

Gland materials are not torn and do not leak.

Foam systems bonded to concrete surface and do not leak.


05832: EXPANSION JOINT



F) MODULAR EXPANSION JOINT - SECTION 05835

General

This item includes the materials and placement for modular expansion joints and associated forming, false work, shoring, and concrete headers.

Most bridges have joints that are designed and constructed to allow for the bridge to defl ect and rotate under traffi c and to expand or contract with changes in temperature. For smaller bridges under approximately 250 feet or less, “relief joints” are used. For larger bridges (greater than 250) simple expansion joints are used. For bridges with larger movements, more complex modular expansion joints are used.

Terminology

Expansion joints are available in a variety of confi gurati ons.

A relief joint is typically a small (appoximately1/2”) verti cal plane that is formed or cut at the end of the deck and approach slab and fi lled with tar or asphalti c fi ller to allow for longitudinal movement and rotati on. Relief joints are used for smaller bridges and similar to concrete paving joints. Specifi cati ons for relief joints are covered in specifi cati on 07922 and other specifi cati ons.

Simple Expansion Joints are typically used where the movement is between 1-4 inches. The most common system is a Strip Seal Expansion Joint and uses two preformed steel channels that have a neoprene gland that is inserted between the steel rails to allow for expansion. An alternate and less common simple expansion joint is a Rigid Plasti c Foam Expansion

Page | 59

CHAPTER 6


Joint which includes a preformed (polystyrene) material that is inserted between the two concrete surfaces to allow for expansion. Strip seal and polystyrene joint systems are in other specifi cati ons.

Structural joints that require several glands or more complex mechanical mechanisms are categorized as Modular Expansion Joints. Modular joints are covered in this secti on.

Modular Expansion Joints require material certi fi cati ons and shop drawings. The Inspector and Resident Engineer are responsible to forward shop drawings to UDOT’s Structures Division for review and approval. In additi on, they are responsible to ensure that the joint systems are properly installed. Buy America requirements apply for Federally funded projects.



1. Material certi fi cati ons for steel and reinforcing.

2. Shop Drawings.

3. Concrete mix designs if concrete headers are required.

Common Issues

Document and noti fy a Structural Engineer if these common issues are identi fi ed:

1. Shop Drawings are delayed or missing.


3. Expansion system is damaged.

4. Poor fi t.

Pre-Inspection Submit Shop Drawings for approval as per specifi cation 05120.

Submit Material certifi cations for steel and rebar.

Buy America Documentation.

Field Inspection & Documentation Proper fi t. Will not affect expansion, ride or plowing operations.

Material – Concrete Tests for Header Materials.

Forming and bracing plan during installation.

05835: MODULAR EXPANSION JOINT



G) WATERPROOFING MEMBRANE - SECTION 07105

General

This item includes procedures for applying a waterproofi ng membrane for bridge decks and other structural surfaces. Waterproofi ng membranes are used to create a physical barrier to seal out water and deicing salts. Once applied, the membranes are covered with an asphalt wearing surface. If improperly installed, the waterproofi ng membranes can trap water and accelerate deteriorati on of the bridge deck.

Inspecti on

Waterproofi ng membranes must be applied to a clean, dry deck surface. Without this criti cal step, the membrane is suscepti ble to leaking. The fi rst step of the waterproofi ng membrane system is to clean the deck using a sand blasti ng operati on. Waterproofi ng membranes are commonly applied for both new constructi on and deck rehabilitati on. The Inspector should ensure that the deck surface has been repaired of any defects prior to sand blasti ng and applying the membrane.

The waterproofi ng membranes are available in two methods; prefabricated or hot pour. Prefabricated membranes require material certi fi cati ons and are to be applied to manufacturer’s specifi cati ons. For either method, the existi ng deck surface should be free of sharp edges and protrusions that may damage its ability to seal water. Hot pour membranes are to be applied at specifi ed applicati on rates, thicknesses and temperatures. Prefabricated membranes are applied using primer materials and are to be inspected for bonding, surface defects, and overlap of joints. Either system should be protected from traffi c unti l the asphalt overlay has been installed.


The following items are required for submitt al:

1. Manufacturer’s product data

2. Recommended installati on instructi ons.

Page | 61

CHAPTER 6


Common Issues

The following are common issues with waterproofi ng membranes:

1. Existi ng deck defects are not properly repaired.

2. Sand blasti ng equipment breaks down.

3. Deck surface is not adequately cleaned.

4. The deck surface is not dry.

5. Primer is not applied properly.

6. Hot pour membranes are not uniformly applied.

7. Resins are improperly mixed by proporti on or quickly dispersed.

8. Contractor does not wrap membrane on parapet surfaces.

Pre-Inspection Verify sand blasting equipment meets the job size and complexity.

Discuss common issues with contractor prior to applying membrane.

Verify deck surface is clean and dry and free of defects.

Verify material certifi cations.

Field Documentation Inspect and verify shot blasting operations.

Inspect and Verify deck is clean and dry.

Inspect and verify hot pour membranes are applied uniformly.

Inspect and verify preformed membranes are properly placed with overlap dimensions.

Protect membrane from traffi c until asphalt overlay is placed.


07105: WATERPROOFING MEMBRANE



6.6 STRUCTURAL REPAIRS AND MODIFICATIONS

A) APPROACH SLAB JACKING - SECTION 03605

General

This item includes the materials and constructi on requirements for lift ing (jacking) of bridge approach slabs. Approach slabs are installed on most bridges to provide a smooth transiti on between the bridge and pavements. As a bridge is constructed, the fi ll materials behind the abutments oft en sett le with ti me creati ng a void or sett lement of the approach slabs. These voids can be fi lled and the approach slab lift ed by injecti ng a cement or urethane material. This specifi cati on relates to the materials and constructi on methods for cement based materials. Special provisions should be reviewed for urethane materials.

Constructi on and Inspecti on

Approach slab jacking consists of drilling a 1-2” diameter hole through the approach slab, att aching a nozzle and injecti ng a concrete grout material to fi ll the void and lift the approach slab. Inspector responsibiliti es include review and approval of the materials, mixing of the grout, drilling of holes, injecti on, fi nished profi le (ride), and clean up processes. Some newer approach slabs use post-tensioned cables. Drilling of these approach slabs should only be done with the review and approval of a Structural Engineer.






Page | 63

CHAPTER 6


Common Issues

The following are common issues with approach slab jacking:

1. Concrete/grout materials do not have approved mix design.

2. Reinforcing steel is damaged during drilling process.

3. Contractor lift s the approach slab too high (poor ride).

4. Contractor uses more materials than expected.

5. Contractor does not clean up waste materials.

6. Materials tests do not meet requirements.


Pre-Inspection Contractor to Submit concrete mix design for approval.

Contractor to give prior notice of schedule for inspection & material testing.

Inspector to ensure adequate equipment for mixing and injecting.

Inspector to ensure reinforcement in proper placement.

Ensure approach slab does not have post tensioning strands.

Field Documentation Ensure concrete meets air entrainment and slump requirements.

Ensure that mixing and pumping equipment is properly used.

Ensure that drilling does not damage reinforcing steel.

Inspect injection process and lifting of panels to avoid raising panels too high.

Document materials, labor and equipment used.

03605: APPROACH SLAB JACKING



B) STRUCTURAL CONCRETE REPAIR AND SEALING - SECTION 03924

General

This item includes the materials and constructi on requirements for repairs and rehabilitati on to structural concrete. Common structural items include columns, piers, pier caps, abutments and other exposed concrete surfaces. Concrete deck repairs are covered under other specifi cati ons.


Rehabilitati on and repairs of structural concrete vary for each bridge. Repairs may be intended to gain a few additi onal years of life or to provide extensive rehabilitati on. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the constructi on process for approval, extent (scope) of work and anti cipated results. The Inspector should discuss questi ons and concerns with the design Engineer if needed.

Most structural concrete repairs include removing delaminated or damaged concrete, cleaning and repairing reinforcing steel, and placing new concrete materials over the repaired areas. The Inspector should ensure that the requirements of the plans and special provisions are met. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated concrete does not damage surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete patching materials need to be approved and inspected to ensure they will bond with the existi ng concrete and have an acceptable fi nish.

Page | 65

CHAPTER 6




1. Equipment list and methods for removal of deteriorated concrete.

2. Material Certi fi cati ons or mix design for concrete patching materials, crack injecti on materials, and concrete seals.

3. Certi fi cati ons of labor for epoxy injecti on operators.

4. Girder jacking and shoring plan for beam end repairs.

5. Prior noti fi cati on of schedule to remove and place new concrete materials.

Common Issues



2. Reinforcing steel or surrounding concrete is damaged during removal process.

3. Quanti ty overages if paid by the quanti ty.

4. Does not remove enough deteriorated areas if paid by lump sum.

5. Poor fi nish and bonding of new patching materials.


7. Materials tests do not meet test requirements.


Pre-Inspection Contractor to Submit material certifi cations or mix designs. Contractor to give prior notice of schedule for inspection & material testing. Inspector to ensure properly sized equipment for removal, and repairs. Certifi cations of labor for epoxy injection. Girder shoring and lifting plans if required.

Field Documentation Ensure removal does not damage surrounding concrete or structure. Ensure that proper equipment is used. Ensure that materials meet specifi cations. Verify and document quantities of areas to be repaired. Document labor, equipment, and materials used.

Ensure bonding and fi nish of patching materials.

03924: STRUCTURAL CONCRETE REPAIR & SEALING



C) SLOPE PROTECTION REPAIR - SECTION 03932

General

This item includes the materials and constructi on requirements for repairing slope protecti on on bridge structures. Slope protecti on is commonly used to eliminate erosion on the slopes underneath a bridge structure. They are typically made of concrete and reinforced with a welded wire fabric. Slope protecti on occasionally sett les or becomes damaged requiring repair. Most repairs involve the replacement of several panels as specifi ed in the plan package.


The extent of slope protecti on repairs can vary from a few panels to an enti re slope. The Inspector must exercise judgment in the fi eld to verify actual quanti ti es to be repaired. Slope protecti on deteriorati on is typically caused by water undermining the concrete. Any repairs should also consider the correcti ng the source of the erosion such as damaged deck drains. Slope protecti on repairs typically involve removing the damaged concrete, repairing underlying bedding materials,

placing welded wire reinforcement and casti ng new concrete. The welded wire fabric and concrete are covered in other specifi cati ons.

Inspector responsibiliti es include review and approval of the materials, sati sfactory removal of damaged areas, preparing a stable grade, proper placement of the reinforcement, and fi nishing of new concrete.

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2. Certi fi cati ons for welded wire fabric and granular borrow.



Common Issues



2. Underlying drainage problems that require additi onal repairs.

3. Quanti ti es in fi eld are greater than shown on plans.

4. Finishing problems due to slope and wrong slump of concrete.

5. Reinforcing fabric is not placed properly.


7. Materials tests do not meet requirements.


Pre-Inspection Contractor to Submit concrete mix design for approval. Contractor to give prior notice of schedule for inspection & material testing. Contractor to submit certifi cations for materials. Inspector to verify plan quantities and locations before removal process starts.

Field Documentation Ensure concrete meets air entrainment and slump requirements. Ensure that mixing and pumping equipment is properly used. Ensure base materials and drainage issues have been properly repaired. Ensure welded wire fabric has been properly placed. Ensure concrete is properly placed and fi nished. Document materials, labor and equipment used.

03932: SLOPE PROTECTION REPAIRS



D) PARAPET END MODIFICATIONS - SECTION 03933

General

This item includes the materials and constructi on requirements for modifi cati on repairs to bridge parapet ends. Many older bridges have parapets (concrete barrier) that do not meet current safety standards. As a result, these parapet ends are commonly retrofi tt ed to improve the safety features.


Modifi cati ons and rehabilitati on of bridge parapets vary for each bridge and project. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the constructi on process for approval, scope of work and anti cipated results. The Inspector should discuss questi ons and concerns with the design Engineer if needed.

Most parapet ends modifi cati ons involve removing a porti on of the concrete parapet and att aching upgraded guardrail or barrier. Connecti on details are an important aspect of these repairs. The Inspector is responsible to ensure that safety considerati ons are met as well as the use of proper materials and constructi on practi ces.



1. Equipment list and methods for removal of existi ng parapet concrete.

2. Manufacturers Certi fi cati ons and instructi ons.

3. Material Certi fi cati ons.


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Common Issues

The following are common issues with parapet end modifi cati ons:

1. Concrete materials do not have approved mix design.

2. Reinforcing steel or surrounding concrete is damaged during removal process.


4. Improper fi t or placement of anchor bolts, and connecti on details.

5. Poor fi nish of concrete.




E) STRUCTURAL POTHOLE PATCHING - SECTION 03934

General

This item includes the materials and constructi on requirements for repairs, rehabilitati on for patching of potholes on bridge decks. Concrete deck repairs are one of the most common repairs for a bridge structure. Membranes and overlays systems are typically used with pothole repairs and are covered in other specifi cati ons.

Pre-Inspection Contractor to Submit material certifi cations or mix designs. Contractor to give prior notice of schedule for inspection & material testing. Inspector to ensure properly sized equipment for removal, and repairs.

Field Documentation Ensure removal does not damage surrounding concrete or structure. Ensure that proper equipment is used. Ensure that materials meet specifi cations. Ensure anchors and connection details are properly placed. Ensure guardrail or concrete barrier is attached properly Verify and document quantities of areas that are modifi ed including labor, equipment, and materials used.


03933: PARAPET END MODIFICATION




Rehabilitati on and repairs of concrete decks vary for each bridge. Repairs may range from a few square yards to the enti re deck surface. Deck repairs are intended to improve the ride and increase the life of the bridge. In many cases, the extent of the repairs required is not known unti l work begins. The Inspector needs to adequately review the intent of the plan package and exercise judgment during the constructi on process for approval, extent (scope) of work and anti cipated results. The Inspector should discuss questi ons and concerns with the design Engineer if needed.

The deteriorated areas to be repaired are typically identi fi ed on the plan sheets. The Inspector should verify these locati ons and look for additi onal areas of delaminated concrete. Delaminated areas can be found by “sounding” the deck surface with a steel rod, hammer or dragging a steel chain.

Most structural concrete deck repairs include removing delaminated or damage concrete, cleaning and repairing reinforcing steel, and placing new concrete patching materials over the repaired areas (pothole repairs). Deteriorated concrete can be removed by the use of jackhammers or pressurized water. The Inspector should ensure that the requirements of the plans and special provisions are met. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated

concrete does damage surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete patching materials need to be approved and inspected to ensure they will bond with the existi ng concrete and have an acceptable fi nish.



1. Equipment list and methods for removal of deteriorated concrete.

2. Plan for handling of waste water.

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3. Material Certi fi cati ons or mix design for concrete patching materials, crack injecti on materials, and concrete seals.


Common Issues

The following are common issues with concrete deck pothole repairs:

1. Equipment is too big and damages surrounding concrete. Jackhammers too big or water pressure is too high.



4. Does not remove enough deteriorated areas if paid by lump sum.





9. Deck blow through.

Pre-Inspection Contractor to Submit material certifi cations or mix designs. Contractor to give prior notice of schedule for inspection & material testing. Contractor to submit removal plan including equipment to be used.

Field Documentation Ensure removal does not damage surrounding concrete or structure. Ensure that proper equipment is used. Ensure that materials meet specifi cations. Verify and document quantities of areas to be repaired. Document labor, equipment, and materials used.


03934: STRUCTURAL POTHOLE PATCHING



F) EXPANSION JOINT MODIFICATION - SECTION 05832

General

This item includes the materials and constructi on requirements for the replacement of bridge expansion joint systems. As a bridge ages, the expansion joint systems deteriorate and require replacement to allow the bridge to properly expand with temperature changes and to also seal water from leaking onto other porti ons of the bridge. Related secti ons including structural concrete and structural steel are covered in other specifi cati ons.


Rehabilitati on and repairs of concrete decks typically include the removal and replacement of expansion joint systems. Repairs involve saw-cutti ng and removing a porti on of the surrounding concrete, removal of the existi ng joint system, forming, installati on of a new joint system and casti ng of new header concrete. Joint systems are typically manufactured by one of two nati onal suppliers who will submit shop drawings for the new joint system.

The Inspector needs to ensure:

1. That surrounding concrete and structural items are not damaged during the removal process.

2. Materials are certi fi ed, and shop drawings are approved.

3. New system is constructed to the dimensions and other requirements of the plan package.

4. Special considerati on should be given to installing the joint system to match temperatures during constructi on and for a smooth fi t that will not be damaged by plows or traffi c.

Surrounding concrete is typically removed with jackhammers. The Inspector should ensure that jackhammers and other equipment used to remove deteriorated concrete do not damage

surrounding concrete and structural items. Any exposed reinforcing steel needs to be inspected to ensure that it has been properly sandblasted, cleaned and repaired prior to patching with new concrete materials. Concrete header materials need to be approved and inspected to ensure they will bond with the existi ng concrete and have an acceptable fi nish.

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1. Equipment list and methods for removal of adjacent concrete deck.

2. Plan for handling of waste water during saw-cutti ng.

3. Shop drawings for new expansion joint system.

4. Material Certi fi cati ons or mix design for concrete header materials, crack injecti on materials, and concrete seals.


Common Issues

The following are common issues with expansion joint modifi cati on repairs:

1. Equipment is too big and damages surrounding concrete.

2. Concrete header materials do not have an approved mix design.


4. Poor fi t and ride issues with new joint system.

5. New joint system not set to ambient temperatures.


7. Material tests do not meet test requirements.


Pre-Inspection Contractor to Submit material certifi cations or mix designs. Contractor to submit shop drawings for new joint system. Contractor to give prior notice of schedule for inspection & material testing. Contractor to submit removal plan including equipment to be used.

Field Documentation Ensure removal does not damage surrounding concrete or structure. Ensure that proper equipment is used. Ensure that materials meet specifi cations. Verify new joint system is installed to plan dimensions. Ensure bonding of new concrete to surrounding concrete. Document labor, equipment, materials and time to complete item.

05832: EXPANSION JOINT MODIFICATION



G) SEALING EXISTING CONCRETE SLOPE PROTECTION JOINTS - SECTION 07921

General

This item includes the materials and constructi on requirements for sealing of existi ng concrete bridge slope protecti ons. Reinforced concrete slope protecti ons are used to protect soils and underlying earthwork near bridge abutments from erosion.

As ti me passes and the concrete slope protecti on ages, cracks and openings oft en appear at joints. Left unrepaired, these openings can cause water to undermine the concrete and for the slope protecti on to sett le and fail. To prevent this, existi ng concrete slope protecti ons are oft en repaired and resealed. Slope protecti on repairs are covered in other specifi cati ons. This specifi cati on relates to the sealing materials and installati on.


The extent of slope protecti on repairs can vary from a few panels to an enti re slope. Once repairs are made, the joints and cracks are resealed using pre-manufactured backer material and caulking sealant materials. The backer materials are a foam type material and are covered in other specifi cati ons. The sealant is a pre-manufactured polyurethane material that is shipped in common caulking tube containers.

The Inspector is responsible to ensure that materials meet specifi cati ons, surfaces are clean and prepared, and the sealant is properly installed. Material certi fi cati ons are required for submitt al and approval prior to installati on. The Inspector should visually review and approve concrete surfaces to ensure that weeds and debris have been removed so that the sealant will adhere to the surfaces. The Inspector is also responsible to ensure that the joints and cracks are fi lled with a uniform applicati on of the sealant and fi nished to match the exposed surfaces. Excess materials should be cleaned. Typical areas that require sealant include slope protecti on grid joints, joint surface with the abutment and wingwalls and repairs of cracks.

This item is typically paid by the amount of material placed. The Inspector needs to maintain daily records of producti on including labor, equipment and materials used.

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1. Certi fi cati ons for backer rod materials.

2. Certi fi cati ons of sealant materials.

3. Installati on Plan (labor, equipment and materials).

Common Issues

The following are common issues with concrete slope protecti on sealing:

1. Backer Rod or Sealant materials have not been approved.

2. Surfaces have not been properly cleaned or are not dry.

3. Weather, dryness and temperature.

4. Insuffi cient or excessive applicati on of material.

5. Contractor does not clean up aft er completi on of work.

Pre-Inspection Contractor to submit material certifi cations for approval. Contractor to give prior notice of schedule for inspection. Contractor to submit installation plan. Inspector to verify locations before installation.

Field Documentation Ensure concrete surfaces have been properly prepared and are clean. Ensure that proper equipment is used. Ensure backer rod is installed where appropriate. Ensure sealant material is uniformly and neatly installed. Ensure clean up of waste materials. Document materials, labor and equipment used.

07921: SEALING EXISTING CONCRETE SLOPE PROTECTION JOINTS



H) RELIEF JOINT CRACK SEALING - SECTION 07922

General

This item includes the materials and constructi on requirements for sealing of concrete relief joints on bridges and other structures. Concrete relief joints are commonly used on smaller bridges where the approach slab meets the bridge deck and where the approach slab meets the adjacent pavement. Relief joints are typically a ½" small verti cal joint that is formed or saw cut to allow expansion of the structure. To prevent water intrusion these joints are fi lled with backer rod and a hot applied asphalti c (tar) material.


The installati on process includes preparing the joint surface to ensure it is clean and free of debris, installati on of a backer rod and placement of a hot applied joint material. The Inspector is responsible to ensure the quality of materials and installati on of this process. The contractor should also review a placement plan with the Inspector including labor, equipment and materials to be used. Backer rod and sealant materials require material certi fi cati ons.

The Inspector should visually inspect and verify that the surfaces have been cleaned of existi ng sealant and debris. Backer rods should be inspected to ensure that they are not damaged and installed to the proper depths and dimensions. Hot applied sealants should be inspected for proper heati ng and equipment to apply. The sealant should be applied in a uniform rate that does not under or over fi ll the void.

This item is typically paid by the amount of material placed. The Inspector needs to maintain daily records of producti on including labor, equipment and materials used.



1. Certi fi cati ons for back rod materials.

2. Certi fi cati ons for sealant materials.

3. Installati on Plan (labor, equipment and materials).

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Common Issues

The following are common issues with relief joint sealing:

1. Backer Rod or Sealant materials have not been approved.

2. Insuffi cient equipment or labor to install.

3. Surfaces have not been properly cleaned or are not dry.

4. Weather, dryness and temperature.

5. Insuffi cient or excessive applicati on of material.

6. Contractor does not clean up aft er completi on of work.

I) CLEANING AND REPAINTING STRUCTURAL STEEL - SECTION 09991

General

This item includes specifi cati ons for the materials and applicati on of cleaning and repainti ng systems for structural steel. Structural steel painti ng is performed primarily to extend the life of a structure by slowing the corrosion process. This specifi cati on is for repainti ng systems. Requirements for new painti ng systems are covered in other specifi cati ons.

Pre-Inspection Contractor to submit material certifi cations for approval. Contractor to give prior notice of schedule for inspection & material testing.

Contractor to submit installation plan. Inspector to verify locations before installation.

Field Documentation Ensure concrete surfaces have been properly prepared and are clean. Ensure that proper equipment is used. Ensure backer rod is installed where appropriate. Ensure sealant material is uniformly and neatly installed. Ensure clean up of waste materials. Document materials, labor and equipment used.

07922: RELIEF JOINT CRACK SEALING



The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these two conditi ons are met. In additi on, the Inspector needs to ensure that the paint systems do not adversely aff ect the environment, worker safety, or the traffi c operati ons.

Paint Systems

Painti ng of structural steel does not use a single paint with several coats, but rather a “paint system” that includes proper surface preparati on, several coats of diff erent materials, and defi ned applicati on procedures. UDOT follows general requirements established by the Northeast Protecti ve Coati ngs Committ ee (NEPCOAT). A 3-part coati ng system is required consisti ng of a zinc primer, epoxy or urethane intermediate coat, and aliphati c urethane top coat. Diff erent colors are required for each coat to assist in visual inspecti on of the coverage.

Painti ng Plan




• Source, gradati on and procedures for sandblasti ng and surface preparati on.

• Type and source of solvents and thinning agents. Material informati on and data for each component of the 3 part paint system. This shall include fi lm thickness requirements, Product Safety Data, thinning requirements, temperature requirements, surface profi le (roughness) requirements, mixing instructi ons and equipment recommendati ons.

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Materials Acceptance

In additi on to the requirements of the painti ng quality plan, the contractor and material suppliers are required to submit certi fi cati ons and samples of paint systems for testi ng, review and approval to UDOT’s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to standards.

Painter and Sandblaster Qualifi cati ons

The painter and sandblaster are required to be certi fi ed prior to the contract award by the Society of Protecti ve Coati ngs (SSPC). Diff erent certi fi cati ons are required for painters and sandblasters and for fi eld work and shop work.

Constructi on Inspecti on

The Inspector is responsible to verify the painti ng process including surface preparati on, mixing and blending of paints, applicati on of paint system, safety, equipment and environmental impacts. The Inspector shall verify that surfaces are clean and have a surface profi le that will allow paint to adequately bond to the steel surface. The Inspector will also verify applicati on rates, mill thicknesses, uniformity and quality of the applied paint.







Common Issues









6. Paint is applied at improper applicati on rates, thicknesses or lacks uniformity.

J) CLEANING AND OVERCOATING STRUCTURAL STEEL - SECTION 09992General

This item includes specifi cati ons for the materials and applicati on for cleaning and overcoati ng of existi ng paint systems for structural steel. Structural steel painti ng is performed primarily to extend the life of a structure by slowing the corrosion process. This specifi cati on is primarily intended for spot repairs and overcoati ng of existi ng paint systems to extend the life of the existi ng paint system rather than replacing it. Requirements for new and replacement painti ng systems are covered in other specifi cati ons.

The life of a paint system and its ability to slow corrosion are determined by the quality of the materials and how well they are applied. The Inspector is responsible to ensure that these two

Pre-Inspection Submittal of Painting Plan including requirements of 09972. Painter and Sandblaster qualifi cations. Material Safety Data Sheets. Test samples submitted to Central Materials Paint lab.

Field Documentation Field pre-qualify painters using test area. Verify enforcement of safety plan, including scaffolding, fall protection and work experience.

Ensure paint and other materials are properly shipped and stored. Provide readily available MSDS sheets and product information. Ensure surfaces are clean and prepared to acceptable profi le and free of debris and dust.


09991: CLEANING & REPAINTING STRUCTURAL STEEL

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CHAPTER 6


conditi ons are met. In additi on, the Inspector needs to ensure that the paint systems do not adversely aff ect the environment, worker safety, or the traffi c operati ons.

Paint Systems

Painti ng of structural steel does not use a single paint with several coats, but rather a “paint system” that includes proper surface preparati on, several coats of diff erent materials, and defi ned applicati on procedures. UDOT follows general requirements established by the Northeast Protecti ve Coati ngs Committ ee (NEPCOAT). A 3 part coati ng system is required consisti ng of a zinc primer, epoxy or urethane intermediate coat, and aliphati c urethane top coat. Diff erent colors are specifi ed and required for each coat to assist in visual inspecti on of the coverage. Localized areas may require removal and replacement using a 3 part coati ng systems (prime, intermediate and top coats). However the majority of the existi ng paint system will be cleaned and overcoated with 2 coats (intermediate and top coats). Specifi c areas requiring replacement versus overcoati ng are typically identi fi ed in the plan package, but require verifi cati on in the fi eld by the Inspector and Engineer.

Painti ng Plan




• Source, gradati on and procedures for sandblasti ng and surface preparati on. Type and source of solvents and thinning agents.

• Material informati on and data for each component of the 3 part paint system. This shall include fi lm thickness requirements, Product Safety Data, thinning requirements, temperature requirements, surface profi le (roughness) requirements, mixing instructi ons and equipment recommendati ons.

Materials Acceptance

In additi on to the requirements of the painti ng quality plan, the contractor and material suppliers are required to submit certi fi cati ons and samples of paint systems for testi ng, review and approval from UDOT’s Central Materials Paint lab. UDOT will test paint samples from each batch or lot prior to use and will reject or approve paints in comparison to standards.



Painter and Sandblaster Qualifi cati ons

The painter and sandblaster are required to be certi fi ed by the Society of Protecti ve Coati ngs (SSPC) prior to the contract award. Diff erent certi fi cati ons are required for painters and sandblasters and for fi eld work and shop work.

Constructi on Inspecti on

The Inspector is responsible to verify the locati on of areas to receive paint replacement and overcoati ng. The Inspector is also responsible to ensure the painti ng process including surface preparati on, mixing and blending of paints, applicati on of paint system, safety, equipment and environmental impacts. The Inspector verifi es that surfaces are clean and have a surface profi le that will allow paint to adequately bond to the steel surface. The Inspector verifi es applicati on rates, mill thicknesses, uniformity and quality of the applied paint.







Common Issues







6. Paint is applied at improper applicati on rates, thicknesses or lacks uniformity

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Pre-Inspection Submittal of Painting Plan including requirements of 09972. Painter and Sandblaster qualifi cations. Material Safety Data Sheets. Test samples submitted to Central Materials Paint lab.

Field Documentation Field pre-qualify painters using test area. Verify enforcement of safety plan, including scaffolding, fall protection and work experience.

Ensure paint and other materials are properly shipped and stored. Ensure surfaces are clean and prepared to acceptable profi le and free of debris and dust.


09992: CLEANING & OVERCOATING STRUCTURAL STEEL

Construction Inspection Guide Chapter Links

1-Preface & Introduction

2-Traffic Control

3-Demolition and Earthwork

4-Drainage

5-Pavement & Materials

6-Structures

7-Traffic Signals, Lighting, ATMS

8-Striping, Signing, Safety Features

9-Landscaping, Fencing, Incidental Const.

10-Utilities

11-PDBS

12-Crash Cushion & Barrier End Treatments

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http://issuu.com/tlcs/docs/udot_ci_chapter_11plusapdxjf?mode=window&viewMode=doublePage

http://issuu.com/tlcs/docs/udot_ci_chapter_12_appgf?mode=window&viewMode=doublePage

Construction Inspection Guide

udot.utah.gov/go/construction

http://www.udot.utah.gov/main/f?p=100:pg:0:::1:T,V:197

UDOT Construction Inspection Guide - Chapter 6

Documents

Transcript of UDOT Construction Inspection Guide - Chapter 6