Attachment B - Specifications~1.pdf

OREGON DEPARTMENT OF TRANSPORTATION

SPECIAL PROVISIONS

FOR

Bridge

Bridal Veil Bearing Repair Columbia River Highway

Multnomah County

PROFESSIONAL OF RECORD CERTIFICATION:

Expires 6/30/2022

I certify the Special Provision Section(s) listed below are applicable to the design for the subject project for Bridge 06671/06671A . Modified Special Provisions were prepared by me or under my supervision.

Section(s):

00255,00530,00535,00536,00538,00540,00542, 00585,02001,02050, and 02510

FINAL ELECTRONIC DOCUMENT AVAILABLE UPON REQUEST

OREGON DEPARTMENT OF TRANSPORTATION

FOR

Bridge Bridal Veil Bearing Repair Columbia River Highway

Multnomah County

PROFESSIONAL OF RECORD CERTIFICATION:

Seal w/signature

I certify the Special Provision Section(s) listed below are applicable to the design for the subject project for Traffic Control.

Modified Special Provisions were prepared by me or under my supervision.

Section(s) 00220, 00221, 00222, 00223, 00224, and 00228.

FINAL ELECTRONIC DOCUMENT AVAILABLE UPON REQUEST

SPECIFICATIONS

Work to be performed under this “Bridal Veil Bearing Repair” contract consists of joint and bearing repairs on structures 06671 and 06671A located at the I-84 Bridal Veil Interchange, (mile point 28.10), in Multnomah County. The work also includes temporary work zone traffic control, erosion control, and all other additional and incidental work necessary to complete the Work according to the plans and specifications.

All work shall be completed by December 10, 2021.

In addition to the Department of Administrative Services (DAS) General Conditions for Public Improvement Contracts, sections 00200 and beyond of the 2021 Oregon Standard Specifications for Construction (Standard Specifications) apply to this Contract.

Some sections of the Standard Specifications are identified and modified in the Special Provisions below. Sections of the Standard Specifications not identified in the Special Provisions remain applicable to the Contract according to their original terms.

Unless they are identified in the Special Provisions, sections of the Standard Specifications in Part 00100 – General Conditions are not applicable to this project. When in conflict, the DAS General Conditions for Public Improvement Contracts takes precedence over the Standard Specifications.

Bidders can access the General Conditions for Public Improvement Contracts at https://www.oregon.gov/das/Procurement/Guiddoc/GenCon4PI.pdf

Bidders can access the Standard Specifications online at https://www.oregon.gov/ODOT/Business/Pages/Standard_Specifications.aspx

SECTION 00220 - ACCOMMODATIONS FOR PUBLIC TRAFFIC

Comply with Section 00220 of the Standard Specifications modified as follows:

00220.02(a) General Requirements - Add the following bullet(s) to the end of the bullet list:

• When performing trench excavation or other excavation across or adjacent to a Traffic Lane on a roadway having a pre-construction posted speed greater than 35 mph, backfill the excavation, install surfacing, and open the roadway to traffic by the end of each work shift. Install a "BUMP" (W8-1-48) sign approximately 100 feet before the backfilled area and a "ROUGH ROAD" (W8-8-48) sign approximately 500 feet ahead of the "BUMP" sign. If this requirement is not met, maintain all necessary lane or shoulder closures and provide additional TCM, including flagging, at no additional cost to the Agency. Do not use temporary steel plating to reopen the roadway.

00220.40(e)(1) Closed Lanes - Replace this subsection, except for the subsection number and title, with the following:

One or more Traffic Lanes may be closed on the following roadways and ramps when allowed, shown, or directed during the following periods of time except as specified in 00220.40(e)(2):

A) Columbia River Highway (I-84) Eastbound and Westbound

Single lane closures in each direction are allowed:

Nightly, Sunday night through Friday morning, between 7:00 p.m. and 7:00 a.m.

Nightly, Friday night through Sunday morning, between 8:00 p.m. and 8:00 a.m.

Shoulder closures are allowed at any time on any day of the week.

B) Historic Columbia River Highway (OR100)

Lane closures under flagger control are allowed:

Daily, Monday morning through Thursday afternoon, between 9:00 a.m. and 3:00 p.m.

Nightly, Sunday night through Friday morning, between 7:00 p.m. and 7:00 a.m.

Nightly, Friday night through Sunday morning, between 7:00 p.m. and 8:00 a.m.

C) Bridal Veil Interchange Ramps

Closures of the entrance ramp or exit ramp are allowed:

Nightly, Sunday night through Friday morning, between 8:00 p.m. and 5:30 a.m.

Nightly, Friday night through Sunday morning, between 8:00 p.m. and 7:00 a.m.

One Traffic Lane may be closed on all other adjacent Roadways within the Project Site not listed above, when allowed, shown, or directed during the following periods of time except as specified in 00220.40(e)(2):

• Daily, Monday morning through Thursday evening, between 9:00 a.m. and 4:00 p.m.

• Friday, between 9:00 a.m. and 3:00 p.m.

• Friday night through Saturday morning, between 7:00 p.m. and 7:00 a.m.

• Saturday night through Sunday morning, between 7:00 p.m. and 8:00 a.m.

• Nightly, Sunday night through Friday morning, between 7:00 p.m. and 7:00 a.m.

00220.40(f) Limited Duration Ramp Closure – The Contractor will be permitted to close the I-84 eastbound exit ramp and westbound entrance ramp at Bridal Veil Interchange during the concrete repair and bearing and joint replacement work. Ramp closures are allowed once for four consecutive days, starting at 8:00 p.m. on the first day and ending at 10:00 a.m.

on the fourth day during the following periods of time:

Before Friday, October 8, 2021, between Sunday at 8:00 p.m. and Friday at 10:00 a.m.

Friday, October 8, 2021 through Monday, May 9, 2022 on any day of the week After Monday, May 9, 2022, between Sunday at 8:00 p.m. and Friday at 10:00 a.m.

Do not close the ramp until all materials and equipment are on hand or guaranteed to be delivered so that the work can be done in an efficient manner with a minimum period of lane closure.

The ramp closure will not be allowed until the area and detour route are signed according to the TCP and the requirements of Section 00221 and 00222.

Add the following subsection:

00220.41 Bridge Work - Before starting any grading or Pavement removal at Bridge ends or removal of Pavement from Bridge decks, arrange so that all Equipment, labor, and Materials required to complete the Pavement replacement Work and Bridge deck waterproofing Work are on hand or are guaranteed to be delivered. Once grading and Pavement removal begins, vigorously prosecute and complete this Work. Complete paving and membrane waterproofing Work in the shortest possible time.

Temporarily taper or bevel longitudinal and transverse grade changes or drop-offs resulting from grading and Pavement removal and membrane waterproofing Work with asphalt concrete mixture to provide a smooth and safe transition. Construct tapers according to 00620.40.

00220.42 Bridge Site Road Closure - Close the road to traffic at the Bridge site during reconstruction of the Bridge. Do not close the road until all Materials and Equipment are on hand or guaranteed to be delivered so that the Work can be done in an efficient manner with a minimum period of road closure.

The road closure will not be allowed until the area and the detour route are signed according to the TCP and the requirements of Section 00221 and Section 00222.

00220.45 Load Restrictions on Bridges - Limit the combined weight of construction vehicles, Equipment, and daily Material usage to 65,000 pounds for every 1,000 square feet of surface area plus the weight of long term storage of Materials to 25,000 pounds for every 100 square feet of surface area of the Bridge or a total of 200,000 pounds for each span of the Bridge, whichever is less.

The Contractor may request alternate loadings by submitting, 30 Calendar Days before proposed loadings, stamped loading calculations and data according to 00150.35.

SECTION 00221 - COMMON PROVISIONS FOR WORK ZONE TRAFFIC CONTROL

Comply with Section 00221 of the Standard Specifications modified as follows:

00221.03 Traffic Safety and Operations - Replace the bullet that begins “When paving operations create…” with the following bullet:

• When paving operations create an abrupt or sloped edge drop off greater than 1 inch, protect traffic by installing signing according to the "2 Lane, 2 Way Roadway Overlay Area" detail shown on the Standard Drawings. Protect longitudinal and transverse Pavement joints by placing and maintaining an asphalt concrete wedge according to 00221.07(c)(1).

00221.07(c)(1) Paving - Replace this subsection, except subsection number and title, with the following:

When the longitudinal joint is greater than 1 inch in height, install additional TCD according to 00221.03. Complete the placing of ACP and construction of paving joints according to 00735.48, 00735.49, 00743.45, 00744.44, 00744.45, 00745.47, and 00745.48, as applicable.

00221.90(b) Temporary Protection and Direction of Traffic - Delete the bullet that begins “Moving temporary barrier to and from Contractor’s stockpile areas”.

SECTION 00222 – TEMPORARY TRAFFIC CONTROL SIGNS

Comply with Section 00222 of the Standard Specifications modified as follows:

00222.40(e) Temporary Sign Placement - Add the following to the end of the bullet list:

• Install a 54-inch "TRUCKS LEAVING HIGHWAY XXXX FT" sign in advance of each entrance point to the Work Area at sign spacing “A” from the “TCD Spacing Table” shown on the Standard Drawings. Install a 54-inch "TRUCKS ENTERING HIGHWAY XXXX FT" sign in advance of each exit point from the Work Area at sign spacing “A” from the “TCD Spacing Table” shown on the Standard Drawings.

• Install "ROAD WORK AHEAD" (W20-1-48) signs with a 36 by 24-inch "FINES DOUBLE" (R2-6aP) rider on the Columbia River and Historic Columbia River Highways, according to the "TCD Spacing Table" shown on the Standard Drawings or as modified by the Plans except do not install the "FINES DOUBLE" rider on concrete barrier mounted signs.

• Install beyond each end of the Project, facing outgoing traffic, an "END ROAD WORK" (CG20-2A-24) sign a distance of (A ÷ 2) according to the "TCD Spacing Table" shown on the Standard Drawings or as modified by the Plans.

• When the horizontal clearance for the Roadway is less than 19 feet, install horizontal clearance (CW21-12-48) signs, identifying the narrowest width of the Roadway. Locate these horizontal clearance signs as shown or as directed.

• Install two sign flag boards, as shown on the Standard Drawings, above the following detour and road closed advance warning signs, where applicable:

• "DETOUR AHEAD", "DETOUR XXXX FT", "DETOUR X/X MILE" (W20-2) signs.

• "ROAD CLOSED AHEAD", "ROAD CLOSED XXXX FT", "ROAD CLOSED X/X

MILE" (W20-3) signs.

• For paving operations on non-freeways, place “ABRUPT EDGE” (CW21-9) and “ROAD WORK XX MPH” (CW20-1a) signs as shown. Use an “XX” value equal to 10 mph below the current posted regulatory speed. If a speed is posted for a temporary regulatory speed reduction, that speed is the current posted regulatory speed.

• For all other moving operations that do not create an abrupt edge adjacent to traffic, omit the “ABRUPT EDGE” signs.

SECTION 00223 - WORK ZONE TRAFFIC CONTROL LABOR AND VEHICLES

Comply with Section 00223 of the Standard Specifications.

SECTION 00224 - TEMPORARY TRAFFIC CHANNELIZING DEVICES

Comply with Section 00224 of the Standard Specifications modified as follows:

00224.46 Pavement Edge Delineation - Replace the paragraph that begins “Place tubular or conical markers…” with the following paragraph:

Place tubular or conical markers to delineate the edge of Pavement immediately after construction Work or paving operations create an abrupt or sloped edge drop-off greater than 1 inch in height along the right hand or left hand Shoulder.

SECTION 00228 - TEMPORARY PEDESTRIAN AND BICYCLIST ROUTING

Comply with Section 00228 of the Standard Specifications modified as follows:

00228.00 Scope - Replace this subsection, except subsection number and title, with the following:

In addition to the requirements of Section 00221, this Work consists of furnishing, installing, operating, maintaining, inspecting, and removing temporary devices for accommodating pedestrians and bicyclists through a work zone.

00228.80(a) Length Basis - Replace this subsection, except subsection number and title, with the following:

Pedestrian channelizing devices and bicycle channelizing devices will be measured on the length basis upon delivery to the Project. The quantities will be limited to those in the approved TCP.

SECTION 00255 - TEMPORARY BRIDGE JACKING

Section 00255, which is not a Standard Specification, is included in this Project by Special Provision.

Description

00255.00 Scope - This Work consists of temporarily raising and shoring the existing Spans located at bents __7 and 5E_______, with jacking system for the purpose of replacing bearings______. Once the Work is completed, the span will be lowered back into place and the jacking system removed.

The term “jacking system” includes jacking equipment, temporary support seat, falsework jacking bent or temporary corbel.

00255.02 Plans - Plans for the existing structure are available from the Engineer. Prints of these plans are available upon request.

00255.03 Submittals - Submit a stamped and detailed Bridge jacking work plan according to 00150.35, to the Engineer for review four weeks prior to Bridge jacking work. Design the work plan according to with the current AASHTO LRFD Bridge Design Specifications and jacking load diagram shown on the Plans. Design the temporary support to carry all structure dead loads, live loads if allowed and construction loads.

Include the following information in the submittal:

• The proposed method of the jacking, and shoring.

• Descriptions of equipment to be used

• Descriptions and values of all loads, including construction equipment loads

• Justification for allowable bearing stresses used to support the falsework bent.

• Complete details and calculations for jacking and supporting the existing structure

This review does not relieve the Contractor of the responsibility for the safety of the method or Equipment. Do not perform Work until the work plan has been approved by the Engineer and all comments are adequately addressed.

00255.04 Methods and Monitoring System - The Bridge jacking work plan includes, but is not limited to, the following:

• Detailed time schedule of the planned operations.

• Details to temporarily strengthen the existing Bridge members. Provide temporary supports to bear directly on girder stems or bent caps or bear on support sills which are structurally adequate to transmit the load to the stems or cap without overstressing any member of the new or existing structure. Design temporary supports not to induce permanent forces into the completed structure or produce cracking.

• Contingency plans to address potential malfunctions or interruptions in the work plan.

• Details of how secondary supports, such as blocking and cribbing, will be installed after the Bridge has been raised.

• Equipment that ensures uniform lifting of the Bridge.

• Descriptions of the displacement monitoring system. Include in the displacement monitoring system, but not limited to:

• Equipment to be used,

• Location of control points,

• Method and schedule of taking measurements,

• Provisions to jack the structure if settlement occur in the temporary supports during construction.

Construction

00255.50 Jacking Operations:

(a) General - Control and monitor the jacking operations to ensure that the jacking loads are applied simultaneously to prevent distortion and excessive stresses that would damage the structure. Jack the superstructure as necessary to maintain the total vertical displacements at control points to less than 1/4 inch from the elevations recorded prior to jacking or as modified by the Engineer.

Remove attachments from the existing structure and concrete surfaces to restore to original conditions, except where permanent alterations are shown on the plans.

(b) Unanticipated Displacements - If, during construction, unanticipated displacements, cracking or other damage occur, do the following:

• Discontinue the construction until corrective measures satisfactory to the Engineer are performed.

• Repair damage to the structure as a result of the Contractor's operations.

Measurement

00255.80 Measurement - No measurement of quantities will be made for Work performed under this Section.

Payment

00255.90 Payment - The accepted quantities of Work performed under this Section will be paid for at the Contract lump sum amount for the item “Bridge Jacking at Bent _____”.

The Bent number will be inserted in the blank.

Payment will be payment in full for furnishing the Bridge jacking work plan, furnishing and placing all Materials, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified.

No separate or additional payment will be made for designing, constructing, maintaining, inspecting, or removing the temporary Bridge jacking.

SECTION 00280 - EROSION AND SEDIMENT CONTROL

Comply with Section 00280 of the Standard Specifications modified as follows:

00280.06 Erosion and Sediment Control Manager - Delete this subsection.

00280.62 Inspection and Monitoring - Replace this subsection, except for the subsection number and title, with the following:

Inspect the Project Site and all ESC devices for potential erosion or sediment movement on a weekly basis and when 1/2 inch or more of rainfall occurs within a 24-hour period, including weekends and holidays.

If a significant noncompliance or serious water quality issue occurs that could endanger health or the environment, verbally report it to the Engineer within 24 hours.

00280.90 Payment - In the paragraph that begins "Item (a) includes...” delete the bullet that specifies "providing the Erosion and Sediment Control Manager".

Replace the paragraph that begins "When only Item (a) is..." with the following paragraph:

Additional ESC devices required for permit compliance will be paid for as Extra Work according to Section 00196.

SECTION 00530 - STEEL REINFORCEMENT FOR CONCRETE

Comply with Section 00530 of the Standard Specifications modified as follows:

00530.80(a) Lump Sum - Add the following to the end of this subsection:

The estimated quantity of reinforcement is:

Structure Number

Uncoated Reinforcement Quantity (Pound)

Grade 60

06671 200

The weight of miscellaneous metal, based on weights listed in 00530.80(b) and Project quantities, is included in the estimated quantity of uncoated reinforcement.

SECTION 00535 - RESIN BONDED ANCHOR SYSTEMS

Replace Section 00535 of the Standard Specifications with the following Section 00535:

SECTION 00535 - POST-INSTALLED ANCHOR SYSTEMS

00535.00 Scope - This Work consists of drilling and preparing holes in hardened concrete and providing and installing anchor bolts and/or reinforcement using a resin bonded anchor system or a mechanical anchor system as shown.

00535.01 Required Submittals - For resin bonded anchor installation horizontally or upwardly inclined submit personnel qualifications according to 00535.30 at least 21 Calendar Days before starting Work.

Materials

00535.10 Materials - Provide the Engineer with:

• Certification, according to 00165.35, that the anchor system meets all requirements for the Project.

• Mill test certificates verifying the strengths of material used in the manufacture of the anchors.

(a) Resin Bonded Anchor System - Furnish anchor bolts meeting the requirements of 02560.30 and reinforcing steel meeting the requirements of Section 02510 as shown.

High strength anchor bolts meeting the requirements of ASTM A193, Grade B7 may be substituted in place of these specified in 02560.30(b).

Furnish a polyester, vinyl ester, or epoxy resin bonding system from the QPL that sustains the minimum pullout force shown. Resin used for installation of the anchor system as shown shall be the same lot used for testing according to 00535.45(a)(1).

Unless shown otherwise, do not install anchors larger than 1 inch in diameter using a resin-bonded anchor system.

Unless shown otherwise, galvanize all anchors which have any portion of the anchor exposed. Galvanize according to AASHTO M 232 (ASTM A153) or AASHTO M 298 (ASTM B695), Class 50. When within 25 aerial miles of the Pacific Ocean, galvanize according to AASHTO M 232 (ASTM A153) only. Anchors that become completely encased in concrete will not require galvanizing.

Provide thread lengths as shown. If thread lengths are not shown and the anchor is not rebar, provide threads on the resin-bonded end of the anchor for at least 80 percent of the embedment depth shown.

(b) Mechanical Anchor System - Furnish a mechanical anchor system from the QPL that sustains the minimum pullout force and is not longer than the embedment depth shown. Anchors used for installation shall be the same lot used for testing according to 00535.45(a)(2). Unless shown otherwise, provide galvanized mechanical anchors according to AASHTO M 232 (ASTM A153).

Labor

00535.30 Qualified Personnel - Provide ACI/CRSI adhesive anchor certified personnel for installation of resin bonded anchors horizontally or upwardly inclined (including vertically overhead). Contact Oregon Chapter of ACI, (503) 753-3075, www.oregonaci.org

00535.40 Construction - Install the anchor system according to the Manufacturer's Printed Installation Instructions (MPII) and to the embedment depths shown.

(a) General - Locate existing reinforcing bars. If existing reinforcement is encountered, adjust the hole location to avoid conflicts as shown or as directed. Avoid installing anchors in cracked concrete. Patch abandoned holes with a PCC repair material meeting the requirements of Section 02015 and according to the manufacturer’s recommendations.

Clean holes with a nonmetallic brush, compressed air, and water. Remove excess water from the hole. The cleaned hole may be damp, but shall be free of concrete dust, foreign matter, and standing water. Protect drilled and cleaned hole from contamination. If the drilled hole becomes contaminated, as determined by the Engineer, re-clean the hole.

Do not install anchors until concrete has cured for 21 Calendar Days.

Provide components connected to the installed anchors with the same metal type or provide electrical isolation when metal type of the components is dissimilar or unknown.

(b) Resin Bonded Anchor System - Unless stated otherwise in the manufacturer's instructions, use a drill bit diameter 1/8 inch larger than the nominal anchor diameter for AASHTO M 314 anchors and 5/64 inch larger than the out-to-out diameter for rebar.

Install horizontally inclined, upwardly inclined, or vertically overhead resin bonded anchors using a piston plug method.

Do not install resin bonded anchors when the concrete temperature is below 50 °F, unless otherwise advised by the resin manufacturer’s recommendations.

For anchors resisting sustained tension loads do not load or torque anchors until 24 hours after the manufacturer’s minimum full cure time.

For resin bonded anchor system with anchor bolts and nuts, after the resin is fully cured, mark the position of the nut with a felt tip pen or similar marker. Rotate the nut of each anchor bolt past snug-tight by no more than 1/6 turn, unless shown otherwise, to avoid unintended damage.

00535.45 Testing - Perform demonstration tests and production tests on anchors as specified in the anchor test summary at the frequency in the MFTP.

Perform demonstration tests before installing the anchor system and perform production tests during anchor installation Work at agreed upon locations.

Do not incorporate demonstration test anchors into the Work. Do not begin installing the anchor system until the installation process is approved. Test results with the average load meeting or exceeding the minimum pullout force will be acceptable. If any test anchor has a capacity less than 95 percent of the minimum pullout force, the anchor lot will be rejected.

(a) Demonstration Tests - Demonstrate the installation process for each lot of post-installed anchor system and each anchor type and size.

Install three test anchors using the same materials and methods that will be used for installing the anchor system. One demonstration test includes 3 test anchors.

(1) Resin Bonded Anchor System - Test the anchors according to ASTM E488 as confined tension tests up to the minimum pullout force shown. When the pullout force and embedment depth are not shown, install the anchors to the embedment depth and test the anchors using the minimum pullout force in Table 00535-1.

Table 00535-1

Minimum Pullout Force

Anchor Bolts Rebar

Grade 36 Grade 55 Grade 105 Grade 60

Dia.

(inch)

Force (Pounds)

Embed Depth (inch)*

Size Force

(Pounds)

Embed.

Depth (inch)*

1/2 7,400 9,700 15,300 4.50 3 7,900 3.25

5/8 11,700 16,900 24,300 6.00 4 14,400 5.25

3/4 17,300 22,500 36,000 7.50 5 22,300 6.50

7/8 24,000 31,200 49,900 9.25 6 31,700 7.50

1 31,700 40,900 65,400 11.00 7 43,800 8.75

8 56,700 10.25 *± 1/8 inch

(2) Mechanical Anchor System - Test the anchors according to ASTM E488 as unconfined tension tests up to the minimum pullout force shown.

(b) Production Tests - Use anchors from the same lot used for the demonstration tests.

Perform production tests during installation of the anchor system, after the installation is finished, and for the Resin Bonded Anchor System the resin has cured according to the Manufacturer’s recommendations. One production test includes 1 test anchor. Maintain the test load at the required load level for a minimum of 10 seconds. Test anchors shall not have measurable displacement. If the Engineer suspects improper installations, more testing may be required.

(1) Resin Bonded Anchor System - Test anchors according to ASTM E488 as confined tension tests to 50 percent of the minimum pullout force shown.

For bent rebar anchors (#5 or smaller), furnish and test a straight bar at the required location. After the Engineer accepts test results, cold bend the bar to dimensions as shown. For epoxy coated rebar, inspect for damage to coating and repair damaged coated areas according to 00530.45. For threaded rods and larger reinforcing bars, furnish and install a sacrificial straight test anchor at a minimum distance of 1.5 times embedment depth away from the required location.

(2) Mechanical Anchor System - Test anchors according to ASTM E488 as unconfined tension tests to 40 percent of the minimum pullout force shown.

(c) Anchor Test Summary - Test the installed anchors according to Table 00535-2 and Section 00165.

Table 00535-2

Str. Anchor Demo. Prod.

# She et

Type (bolt/ rebar)

Size

Grade

Sustained Tension (yes/no)

Test (yes/no)

Test (yes/no)

06671 J03 Rebar 5 60 Yes No Yes 06671 J02 Rebar 4 60 No No Yes

Replace anchors that fail at no additional cost to the Agency.

00535.80 Measurement - No measurement of quantities will be made for post-installed anchor systems.

00535.90 Payment - No separate or additional payment will be made for post-installed anchor systems. Payment will be included in payment made for the appropriate items under which this Work is required.

SECTION 00536 - INTERNAL SHEAR ANCHORS

Comply with Section 00536 of the Standard Specifications.

SECTION 00538 - CRACK INJECTING EXISTING BRIDGES

Comply with Section 00538 of the Standard Specifications.

SECTION 00540 - STRUCTURAL CONCRETE

Comply with Section 00540 of the Standard Specifications modified as follows:

00540.00 Scope – Add the following to the end of this section

This work consists of building the concrete pedestals as shown on plans using concrete mortar specified in 00542.

SECTION 00542 - CONCRETE REPAIR

Section 00542, which is not in the Standard Specifications, is included in this Project by Special Provision.

00542.00 Scope - This Work consists of locating and repairing damage concrete and reinforcement in Structures, and providing mortar or resin buildup over shallow reinforcement.

00542.01 Definitions:

Damaged Concrete - Concrete that is spalled or delaminated due to corroded reinforcement or metal appurtenances such as bearing devices, drains, and conduits; concrete that is debonded from corroded reinforcing bars; concrete with near-surface rock pockets; unsound or delaminated existing patches; and concrete that has been drilled, excavated, or removed during prior maintenance work or during the Work of this Contract.

Hand Patch - Installing hand-troweled repair mortar in concrete cavities up to 0.50 square foot surface area.

Pumped Repair - Installing pumped repair mortar in concrete cavities greater than 0.50 square foot surface area.

Saturated Surface Dry Condition - Surface condition where hardened concrete is thoroughly saturated with water, but any free water has been removed from the surface.

Shallow Rebar - Steel reinforcement with 1/2 inch or less of concrete cover.

Concrete Mortar – Concrete that used to build up pedestals, and corbels using a high strength bag mixes for concrete repair mortar see section 0542.10. Use pumped mortar in confined areas were concrete is difficult to place.

00542.02 Submittals - Submit the following at least 21 Calendar Days before beginning concrete repair Work according to 00150.37. Within 21 Calendar Days after receipt of submittals, the Engineer will review the submittals and designate them in writing as "approved", "approved as noted", or "returned for correction".

(a) Concrete Repair Mortar & Concrete Mortar- Submit before concrete repair work the following:

• A description of all relevant constituents and properties of the material. Data published by manufacturer is acceptable unless certifications of the material characteristics are required by the Specifications.

• For prepackaged products, the manufacturer’s certification that the contents include cement and Aggregate and do not include silica fume, fly ash, or any other porosity-reducing admixture. Provide the proportion (by weight) of portland cement to Sand according to the provisions of 00165.35.

• The Specifications subsection with which each repair mortar complies.

• If proposing alternative repair mortar to those specified in 00542.10, test data demonstrating compliance with 00542.10.

For alternate repair mortar submit three 4 by 8-inch cylinders of repair mortar cast in the presence of the Engineer using the proposed mix proportions, admixtures, and mixing and application Equipment, at least 10 Calendar Days before starting concrete repair Work.

Cast and cure the cylinders according to AASHTO T 23 or R 39.

Submit records of mix proportions and which mix design was used in each repair location.

Maintain and provide records that are complete enough to be able to match repaired areas with the mix records.

(b) Concrete Repair Procedure - Prior to beginning Work under this Section, submit a concrete repair procedure that includes the following:

• Manufacturer’s specifications and operating instructions for all Equipment.

• Details of each step to accomplish the Work.

• Steps to regularly maintain quality control of all newly applied mortar.

• Plan to maintain records of verification of proportion (by weight) of Sand to portland cement and quantity of any additives for all mortar mixed on-site.

• Plan to maintain records identifying the mix design for each repaired area.

(c) Repair Damaged Reinforcing Bars - Submit a plan for accomplishing reinforcing bar repair that includes the following:

• Welder certifications according to AWS D1.4

• Pre-approved welding procedure specification (WPS) or procedure qualification record / welding procedure specification (PQR/WPS)

• Detailed procedure for electrode control measures

• Detailed procedure for achieving, maintaining, and monitoring pre-heat and inter-pass temperatures.

00542.03 Pre-welding Conference - Before beginning concrete repair Work, meet with the Contractor’s supervisory personnel, concrete repair Subcontractor’s supervisory personnel, the Contractor’s certified welding inspector (CWI), and the Engineer at a mutually agreed upon time. The pre-welding conference includes discussion of the Contractor’s quality control responsibilities, documentation requirements, welding procedures and Equipment, and demonstration of welder skills.

Materials

00542.10 Concrete Mortar & Patch Material:

(a) Pumped Repair Mortar - Provide one of the following mortars with the required admixture as specified in 00542.15.

• Pumped BASF MasterEmaco S 440MC (formerly BASF LA Repair Mortar).

Alternative repair mortar conforming to the following:

• Non-polymer flowable micro-concrete

• Suitable for pumping

• At least 4,000 psi 28-Day compressive strength

• “Low” potential for cracking and no cracking in 28 Calendar Days when tested according to ASTM C1581, including Appendix

• Electrical resistivity in the range of 2,000 to 20,000 ohm-cm

Submit proposed alternative Materials for approval according to 00542.02.

(b) Hand Patch Material - Provide hand patching Materials according to 02015.20 or 02015.30. Observe QPL remarks and follow the manufacturer’s recommendation for application.

00542.11 Non-conductive Resin - Non-conductive resin is acceptable for filling cavities of

0.05 square feet or less and for resin buildup over Shallow Rebar in sound concrete. Furnish a non-conductive resin from the category “Concrete Anchor, Resin HS High Strength” of the QPL, mixed at a 1:1 ratio with clean abrasive blasting Material.

00542.12 Abrasive - Furnish clean, dry, non-metallic grit abrasive material with no mineral constituents that break down and remain on the surface in visible quantity. Furnish hard angular shaped abrasives from 16 - 30 mesh.

00542.13 Water - Furnish water according to Section 02020.

00542.14 Reinforcement and Added Steel - Furnish ASTM A706 Grade 60 uncoated reinforcing bars conforming to 02510.10. Furnish uncoated, ungalvanized welded wire fabric conforming to 02510.40. Other metal embedded in the mortar to facilitate concrete replacement shall be uncoated and ungalvanized.

00542.15 Admixtures - Use only admixtures approved by the Engineer.

If using admixtures to reduce the water-cement ratio, or to retard or accelerate the development of strength, use only admixtures compatible with the mortar and at the rate specified by the manufacturer.

000542.16 Hollow Wall Anchors - Furnish the following plastic hollow wall anchors:

• Powers 2345 Nylon Zip-It

• Simpson Strong Tie SWN06 Nylon Sure Wall Drywall Anchor

• ITW Red Head EZP100 Nylon E-Z Drywall Anchor

Labor

00542.30 Welders - Provide certified welders and welding inspectors according to

AWS D1.4.

00542.40 Work Access, Containment, and Disposal - Provide Work access and debris containment according to Section 00253.

Dispose of waste according to 00290.20.

00542.41 Locating and Marking - Locate and mark the following:

• All concrete having visible spalling or delamination due to corrosion of reinforcement or metal appurtenances such as bearing devices, drains, and conduits. Include within the repair boundaries all Damaged Concrete at the edges of spalls.

• All visible unsound patches of material.

• All concrete that is visibly loose, or that becomes dislodged or loosened when struck with a 16-ounce masonry hammer or by other approved technique.

Verify the presence of steel with a metal detector.

The Contractor is advised that concrete containing Aggregate larger than 2 inches can cause false readings. If no steel is present, readings in such areas should be disregarded.

Investigate all spots of rust visually and with a metal detector to determine if a metallic object is present. If a metal object is present mark the location.

In areas where spalling or delamination is not visually detectable, but is indicated by sounding, use a rebar locator and mark reinforcing bars and their minimum concrete cover.

Remove a 4 inch wide (perpendicular to the bar) exploration area centered over the bar. The exploration boundary area shall have an initial length of 8 inches if splitting cracks are present directly over and parallel to reinforcing bar and suggest a potential for corrosion; remove as much splitting crack length as needed until clean bar is exposed. If rust scale or pitting is found on the exposed reinforcing bar, or if the remaining concrete is separated from the bar, mark the Damaged Concrete area for removal.

Do not use internal angles less than 45 degrees in defining the repair boundaries. Make all repairs at least 2 inches wide in each direction. Within these restrictions, mark boundaries such that repair areas can be efficiently sawed and excavated.

Determine and mark the location and extent of each repair excavation. Do not begin concrete removal until location and extent have been verified by the Engineer.

The Engineer will perform verification surveys of selected sections of the Work and determine the final quantity of repairs. Do not begin excavation until the Engineer has completed the verification surveys.

00542.42 Concrete Removal - Saw-cut the boundaries of concrete to be removed, to a depth just missing the reinforcing bars with less than 1/2 inch concrete cover or to a minimum of 1/2 inch, whichever is less. Saw cuts shall not overrun at the corners of the marked boundaries. Saw cutting is not required if the Contractor can consistently provide, by another technique, a minimum 1/2 inch deep excavation surface that is uniformly perpendicular to the original concrete surface along the marked boundary.

Remove concrete within the marked boundaries with high-pressure waterjet blasting Equipment, pneumatic hammers, chipping guns, manual picks and chisels, or other Equipment approved by the Engineer. Do not use pneumatic hammers heavier than a nominal 15-pound class. Remove concrete in such a way that removal of sound concrete beyond established boundaries is kept to a minimum. When working around reinforcing bars, avoid loosening the reinforcement or fracturing the concrete around it beyond the repair area.

Remove all Damaged Concrete within the marked boundaries to the depth of sound concrete.

In areas where the reinforcing bar lacks bond with the existing concrete, continue to excavate to 1/2 inch beyond the depth of the reinforcing bar. In areas where it is difficult to determine if the reinforcing bar lacks bond with the existing concrete do not excavate beyond the depth of the reinforcing bar if a 4 inch wide exploration area shows the reinforcing bar to be free of rust scale or pitting and the reinforcing bar is not separated from the remaining concrete.

The depth of concrete damage, due to corrosion, in any member is not expected to be substantially greater than 1/2 inch beyond the depth of the reinforcing bar.

Do not remove sound concrete over Shallow Rebar.

00542.43 Repair Damaged Reinforcement Bars - Repair reinforcing bar showing 50 percent or greater section loss according to the following:

• Remove all Damaged Concrete

• Remove sound concrete as necessary so that there is a minimum of 3/4 inch clearance between the concrete and splice bars over entire length of repair

• Blast-clean all exposed reinforcing steel and concrete

• If feasible, place splice bars so as to allow 1/2 inch of concrete cover without raising the concrete surface

• Perform all weld splicing according to ANSI/AWS D1.4, “Structural Welding Code - Reinforcing Steel”. Since the carbon content of existing reinforcement is unknown, assume that preheating is required under ANSI/AWS D1.4. Limit the temperature of reinforcing bar at concrete interface to 500 °F or less, verified using an infrared thermometer.

• Remove any additional concrete that cracks or spalls during welding

• Keep the existing spliced bars in place and avoid gouging and loosening reinforcing bar or damaging sound concrete outside of splice areas

• Keep the splice bar in the proper position during placement of concrete cover

Repair round bars with new splice bars the same size as the original bars. Repair square bars with new round splice bars with a diameter equal to the thickness of the square bars.

00542.44 Shallow Rebar in Sound Concrete - If Shallow Rebar exists in sound concrete and passes the sounding test, no concrete repair is necessary.

00542.45 Shallow Rebar in Damaged Concrete - Where directed, treat prefabricated mesh and other closely spaced shallow metals in the same manner as Shallow Rebar in Damaged Concrete. Place additional cover Material over Shallow Rebar in Damaged Concrete according to the following:

(a) Mortar Buildup over Shallow Rebar - Place additional mortar as needed to achieve at least 1/2 inch of cover over Shallow Rebar repairs.

(b) Resin Buildup over Shallow Rebar - In areas where additional buildup is not feasible, or where buildup would detract from the aesthetic appearance of the Structure, provide additional cover using non-conductive resin conforming to 00542.12. Apply the resin in 2 inch wide strips over the Shallow Rebar.

00542.46 Surface Preparation - Abrasive-blast or water-blast all concrete surfaces that are to receive additional mortar cover or patches, to remove all debris, loose concrete, concrete pulverized during removal, scale, and loose rust. Blast exposed reinforcing bars according to SSPC Standard SP6 “Commercial Blast Cleaning” or equivalent procedure. Do not allow prepared surfaces to remain exposed more than 36 hours before placing repair mortar.

Prepare surfaces that are to receive additional mortar or resin cover with a surface profile according to International Concrete Repair Institute (ICRI) Guideline 310.2R-2013 surface profile CSP 6 (1/8 inch surface profile).

Provide hollow wall anchors for concrete surfaces that are to receive more than 1 inch of repair mortar and have reinforcing bar spacing greater than 9 inches. Install anchors by drilling 1/4 inch diameter holes 1/2 to 3/4 inch deep on a 9 inch (maximum) grid in the concrete substrate. Apply non-conductive resin and insert anchors. Remove excess resin from the concrete substrate.

00542.48 Patch Installation:

(a) Forms - Provide smooth-surfaced form Materials. Provide adequate support and bracing of forms to prevent deflection under the weight and pressure of new mortar, and to prevent vibration damage to mortar during setting and curing. Leave forms in place for a minimum of 3 Days after mortar placement.

Provide watertight form Materials and a watertight form system to prevent loss of water during presoaking and repair mortar placement. Incorporate enough pumping ports to ensure consistent placement and enough vent holes or vent tubes to allow air to escape extreme surface irregularities and remote cavities. Limit port spacing to prevent mortar segregation.

Provide forms that can readily be removed and reinstalled for presoaking, flushing, blowdown, and for verification of Surface Saturated Dry Condition.

(b) Pre-soak - Saturate the substrate concrete for at least 24 hours before application of repair mortar. Use either a watertight form kept full of water; saturated burlap or foam Material packed inside the forms, in contact with the entire existing concrete surface, and soaked frequently; or any other method demonstrated to produce Saturated Surface Dry Condition.

After the substrate has been saturated, temporarily remove the form and, immediately before placing mortar, remove all dust, dirt, and other debris by flushing the surface with water pressurized to at least 60 psi, followed by blasting with clean compressed air to remove excess water. Provide a damp surface free of standing water and free of contaminants when applying repair mortar. Light surface rust that appears during the pre-soak stage does not need to be removed. When the concrete surface is in Saturated Surface Dry Condition and free of contaminants, and reinforcement is clean or has only light surface rust, immediately reinstall the forms and place mortar.

(c) Mixing - When a package of prepackaged repair mortar is opened, mix the entire contents of the package.

Mix repair mortar according to the manufacturer’s instructions including, but not limited to, mixing speed, mixing time, and mixing Equipment.

(d) Placing Repair Mortar - Pump repair mortar and achieve thorough and uniform hydration without the use of excess water.

Do not place mortar before acceptance of Saturated Surface Dry Condition by the Engineer.

Do not place mortar during freezing weather or if temperatures are likely to drop below freezing during the cure period for the mortar. Do not apply mortar to frosted surfaces.

Follow the manufacturer’s recommendations regarding temperature and weather conditions during mortar placement.

Provide adequate pumping pressure into each port to ensure mortar completely fills the cavity and mortar is observed at all vents. Vibrate only if approved by the Engineer in advance.

(e) Adjacent Surface Protection - Protect surfaces outside the repair area from mortar overshoot and drip. Remove the excess Material from these areas after the application has been completed.

(f) Mix Records - Record proportion (by weight) of Sand to portland cement and the quantity of any additives for all mortar mixed on-site at the start of each mortar placement operation and every time proportions or additives are changed. Keep a record of which mix is used for each repair area.

00542.49 Curing - Take care to avoid cracks in the new mortar due to excessive surface evaporation. Continuously cure all newly applied mortar according to the manufacturer’s recommended curing schedule.

00542.50 Finish - Finish all exposed surfaces and surface defects to straight and true lines as shown. Provide a Class 2 surface finish according to 00540.53 on all exposed surfaces and a general surface finish according to 00540.53 on all other surfaces, with no coating on any surface unless otherwise directed.

00542.51 Delamination Survey - After mortar repair Work has cured, conduct a delamination survey of all repaired areas with the Engineer according to the following:

• Sound all repaired areas with a 1-pound masonry hammer or by other approved technique.

• Mark boundaries of all delaminations in the repaired areas.

• Identify the marked delamination that needs patching.

Make repairs when delamination repair areas do not meet the acceptance criteria of 00542.52.

Upon completion of the survey, prepare and sign a survey report that identifies all areas to be patched. Submit the survey report for review and acceptance by the Engineer. Repair the identified areas in a manner satisfactory to the Engineer.

After patching the identified areas, repeat the delamination survey. Repeat the delamination survey and repair procedure until all areas of unsound concrete have been repaired and accepted.

Following the bond strength test of cores according to 00542.52(b), the Engineer will visually inspect the cores for sand pockets and voids. If sand pockets or voids are found, the area from which the core was taken will be marked by the Engineer to aid in the Contractor’s delamination survey.

00542.52 Production Quality Control Testing - Acceptance of Work performed under this Section will be according to the following tests:

(a) Compressive Test - For each __100___ square feet of mortar placed on the Bridge, but not less than once per production Work shift, cast at the same time and under the same conditions three 4 by 8 inch cylinders for testing. Cast the cylinders in single-use plastic molds. Cast and cure strength specimens according to AASHTO T 23 or AASHTO R 39. Test the cylinders for compressive strength according to AASHTO T 22 following a 28-Day cure.

The minimum acceptable 28-Day compressive strength of cylinders is __4000___ psi.

(b) Pull-off Test - Following a 7-Day cure of the mortar patch, core one test specimen from each _100____ square feet of newly applied mortar placed on the Bridge surface, at locations designated by the Engineer. Locate cores to avoid damaging reinforcing bar.

Core approximately 1/2 inch into the original concrete. Do not break cores free before testing. Perform pull-off tests of the cores in the presence of the Engineer.

Measure the core bond strength according to ASTM C1583. Use pull-test dollies with the same diameter as the cores. Conduct the test until failure.

The minimum acceptable bond strength between the new and original concrete is 175 psi.

If the test shows failure at less than 100 psi, retest after checking Equipment and verifying core angle is perpendicular to the surface. If the patch area is too small for another test, use alternate patch location. If the retest shows failure at less than 100 psi, then a pull-off test may be performed on in situ concrete substrate in the vicinity of the patch area to determine the existing concrete substrate tensile strength. If in situ concrete substrate fails at 100 psi or less, the Engineer will re-evaluate the original concrete substrate.

Individually seal the cores taken from the Bridge in plastic bags and tag them for identification.

If any quality control test fails to meet the minimum requirements, any or all repair mortar represented by that test may be rejected by the Engineer.

00542.53 Deficient Repair Mortar - Repair, at no additional cost to the Agency, all mortar patches that show an alligator cracking in the surface or uncontrolled cracks visible without magnification. Perform additional testing as directed to determine the extent of deficient mortar in the production test area represented. If additional patches are found to be deficient, repair the production test area represented according to the Specifications at no additional cost to the Agency. Repairs include, but are not limited to, removal and replacement of patches found to be substandard.

Repair small crevices a maximum of 0.4 inch deep and 0.1 inch wide at the edge of a patch with non-conductive resin mixed with abrasive blasting Material or other approved patch Material, at no additional cost to the Agency. Cut out pockets or other defects and replace with new repair mortar according to this Section.

00542.80 Measurement - The quantities of Work performed under this Section will be measured according to the following:

(a)…