IDOT 64T46-047.pdf

Letting June 12, 2026

Notice to Bidders, Specifications and Proposal

Contract No. 64T46 WHITESIDE County Section (115BR)BRR Route FAP 22 Project STP-ZPKD(153) District 2 Construction Funds

Prepared by F

Checked by

(Printed by authority of the State of Illinois)

NOTICE TO BIDDERS

1. TIME AND PLACE OF OPENING BIDS. Electronic bids are to be submitted to the electronic bidding system (iCX-Integrated Contractors Exchange). All bids must be submitted to the iCX system prior to 12:00 p.m.

June 12, 2026 at which time the bids will be publicly opened from the iCX SecureVault.

2. DESCRIPTION OF WORK. The proposed improvement is identified and advertised for bids in the

Invitation for Bids as:

Contract No. 64T46 WHITESIDE County Section (115BR)BRR Project STP-ZPKD(153) Route FAP 22 District 2 Construction Funds

Bridge repairs, deck overlay and joint replacement on SN 098-0103, carrying IL 78 over Coon Creek,

1.8 miles south of Prophetstown.

3. INSTRUCTIONS TO BIDDERS. (a) This Notice, the invitation for bids, proposal and letter of award shall, together with all other documents in accordance with Article 101.09 of the Standard Specifications for Road and Bridge Construction, become part of the contract. Bidders are cautioned to read and examine carefully all documents, to make all required inspections, and to inquire or seek explanation of the same prior to submission of a bid.

(b) State law, and, if the work is to be paid wholly or in part with Federal-aid funds, Federal law requires the bidder to make various certifications as a part of the proposal and contract. By execution and submission of the proposal, the bidder makes the certification contained therein. A false or fraudulent certification shall, in addition to all other remedies provided by law, be a breach of contract and may result in termination of the contract.

4. AWARD CRITERIA AND REJECTION OF BIDS. This contract will be awarded to the lowest responsive and responsible bidder considering conformity with the terms and conditions established by the Department in the rules, Invitation for Bids and contract documents. The issuance of plans and proposal forms for bidding based upon a prequalification rating shall not be the sole determinant of responsibility. The Department reserves the right to determine responsibility at the time of award, to reject any or all proposals, to re-advertise the proposed improvement, and to waive technicalities.

By Order of the Illinois Department of Transportation

Gia Biagi, Secretary

FAP Route 22 (IL 78)

Section (115BR)BRR Whiteside County

INDEX

FOR

SUPPLEMENTAL SPECIFICATIONS

AND RECURRING SPECIAL PROVISIONS

Adopted January 1, 2026

This index contains a listing of SUPPLEMENTAL SPECIFICATIONS, frequently used RECURRING SPECIAL PROVISIONS, and LOCAL ROADS AND STREETS RECURRING SPECIAL PROVISIONS.

ERRATA Standard Specifications for Road and Bridge Construction (Adopted 1-1-22) (Revised 1-1-26)

SUPPLEMENTAL SPECIFICATIONS

Std. Spec. Sec. Page No.

109 Measurement and Payment 202 Earth and Rock Excavation 204 Borrow and Furnished Excavation 207 Porous Granular Embankment 211 Topsoil and Compost 214 Grading and Shaping Ditches 406 Hot-Mix Asphalt Binder and Surface Course 407 Hot-Mix Asphalt Pavement (Full-Depth) 420 Portland Cement Concrete Pavement 502 Excavation for Structures 504 Precast Concrete Structures 509 Metal Railings 522 Retaining Walls 540 Box Culverts 542 Pipe Culverts 550 Storm Sewers 586 Granular Backfill for Structures 601 Pipe Drains, Pipe Underdrains, and French Drains 630 Steel Plate Beam Guardrail 632 Guardrail and Cable Road Guard Removal 644 High Tension Cable Median Barrier 665 Woven Wire Fence 701 Work Zone Traffic Control and Protection 781 Raised Reflective Pavement Markers 782 Reflectors 801 Electrical Requirements 821 Roadway Luminaires

1003 Fine Aggregates 1004 Coarse Aggregates 1010 Finely Divided Minerals 1020 Portland Cement Concrete ……… 1030 Hot-Mix Asphalt 1040 Drain Pipe, Tile, and Wall Drain 1042 Precast Concrete Products 1061 Waterproofing Membrane System 1067 Luminaire ……… 1097 Reflectors 1102 Hot-Mix Asphalt Equipment

Section (115BR)BRR

RECURRING SPECIAL PROVISIONS

The following RECURRING SPECIAL PROVISIONS indicated by an “X” are applicable to this contract and are included by reference:

CHECK SHEET # PAGE NO.

1 X Additional State Requirements for Federal-Aid Construction Contracts 2 X Subletting of Contracts (Federal-Aid Contracts)

3 X EEO

4 Specific EEO Responsibilities Nonfederal-Aid Contracts 5 Required Provisions - State Contracts 6 Asbestos Bearing Pad Removal 7 Asbestos Waterproofing Membrane and Asbestos Hot-Mix Asphalt Surface Removal 8 Temporary Stream Crossings and In-Stream Work Pads 9 X Construction Layout Stakes

10 Use of Geotextile Fabric for Railroad Crossing 11 Subsealing of Concrete Pavements 12 Hot-Mix Asphalt Surface Correction 13 Pavement and Shoulder Resurfacing 14 Patching with Hot-Mix Asphalt Overlay Removal 15 Polymer Concrete 16 Reserved 17 Bicycle Racks 18 X Temporary Portable Bridge Traffic Signals 19 Nighttime Inspection of Roadway Lighting 20 English Substitution of Metric Bolts 21 Calcium Chloride Accelerator for Portland Cement Concrete 22 Quality Control of Concrete Mixtures at the Plant 23 X Quality Control/Quality Assurance of Concrete Mixtures 24 Reserved 25 Reserved 26 Temporary Raised Pavement Markers 27 Restoring Bridge Approach Pavements Using High-Density Foam 28 Portland Cement Concrete Inlay or Overlay 29 Portland Cement Concrete Partial Depth Hot-Mix Asphalt Patching 30 Longitudinal Joint and Crack Patching 31 X Concrete Mix Design – Department Provided 32 Station Numbers in Pavements or Overlays

Section (115BR)BRR i

TABLE OF CONTENTS

LOCATION OF PROJECT

DESCRIPTION OF PROJECT

TRAFFIC CONTROL PLAN

JOINT REPAIR

DIAMOND GRINDING AND SURFACE TESTING BRIDGE SECTIONS

BRIDGE DECK GROOVING (LONGITUDINAL)

AUTOMATED FLAGGER ASSISTANCE DEVICES (BDE)

BRIDGE DECK CONCRETE OVERLAYS

CEMENT, FINELY DIVIDED MINERALS, ADMIXTURES, CONCRETE, AND MORTAR (BDE)

COMPENSABLE DELAY COSTS (BDE)

CONCRETE BARRIER (BDE)

CONCRETE SEALER (BDE)

DECK SLAB REPAIR

HOT-MIX ASPHALT (BDE)

PAVEMENT MARKING (BDE)

PERFORMANCE GRADED ASPHALT BINDER (BDE)

REMOVAL AND DISPOSAL OF REGULATED SUBSTANCES (BDE)

SHORT TERM AND TEMPORARY PAVEMENT MARKINGS (BDE)

SIGN PANELS AND APPURTENANCES (BDE)

SOURCE OF SUPPLY AND QUALITY REQUIREMENTS (BDE)

STRUCTURAL REPAIR OF CONCRETE (BDE)

SUBCONTRACTOR AND DBE PAYMENT REPORTING (BDE)

SUBCONTRACTOR MOBILIZATION PAYMENTS (BDE)

SUBMISSION OF BIDDERS LIST INFORMATION (BDE)

SUBMISSION OF PAYROLL RECORDS – FEDERAL AID CONTRACT (BDE)

SURVEYING SERVICES (BDE)

TEMPORARY CONCRETE BARRIER (BDE)

TEMPORARY RUMBLE STRIPS (BDE)

VEHICLE AND EQUIPMENT WARNING LIGHTS (BDE)

WORK ZONE TRAFFIC CONTROL DEVICES (BDE)

WORKING DAYS (BDE)

Section (115BR)BRR

STATE OF ILLINOIS

SPECIAL PROVISIONS

The following Special Provisions supplement the “Standard Specifications for Road and Bridge Construction, adopted January 1, 2022”, the latest edition of the “Manual on Uniform Traffic Control Devices for Streets and Highways”, and the “Manual of Test Procedures for Materials” in effect on the date of invitation for bids, and the “Supplemental Specifications and Recurring Special Provisions” indicated on the Check Sheet included herein, which apply to and govern the construction of FAP Route 22 (IL 78), Project STP-ZPKD(153), Section (115BR)BRR, Whiteside County, Contract No. 64T46 and in case of conflict with any part, or parts, of said Specifications, the said Special Provisions shall take precedence and shall govern.

LOCATION OF PROJECT

The proposed bridge rehabilitation of Structure SN 098-0103 over Coon Creek is located on Illinois Route 78, 1.8 Miles east of Prophetstown Southern City Limits in Prophetstown Township.

The project is located in Whiteside County, Illinois.

DESCRIPTION OF PROJECT

The work on this project consists of ¾” bridge deck and approach slab scarification, concrete overlay, bridge deck slab repair, bridge joint repair, HMA pavement transition beyond approach to tie back in to existing pavement, and any collateral or incidental work necessary to complete the improvement as shown on the plans and as described herein.

Section (115BR)BRR

TRAFFIC CONTROL PLAN

Effective: January 14, 1999 Revised: January 13, 2017

Standards:

701006 701201 701301 701311 701321 701326

701901

Details:

Work Zone Sign Details (District Standard 34.1) Reflectors (Special) (District Standard 55.1)

Signs:

“BUMP” (W8-1(O)48) signs shall be installed as directed by the Engineer.

When covering existing Department signs, no tape shall be used on the reflective portion of the sign. Contact the District sign shop for covering techniques.

Any plates or direct applied sheeting used to alter signs shall have the same sheeting as the base sign.

No more than one kind of alteration shall be used to alter a sign.

Any post stubs without a sign in place and visible shall have a reflector placed on each post.

Flaggers:

Flaggers shall comply with all requirements and signaling methods contained in the Department’s “Traffic Control Field Manual” current at the time of letting. The flagger equipment listed for flaggers employed by the Illinois Department of Transportation shall apply to all flaggers

Flaggers:

Flaggers shall comply with all requirements and signaling methods contained in the Department’s “Traffic Control Field Manual” current at the time of letting. The flagger equipment listed for flaggers employed by the Illinois Department of Transportation shall apply to all flaggers

Pavement Marking:

All temporary pavement markings that will be operational during the winter months (December through March) shall be paint.

Short term pavement markings on a milled surface shall be paint.

Section (115BR)BRR

Traffic Control and Protection Standard 701321: This work shall be done according to Section 701 of the Standard Specifications and the Typical Application of Traffic Control Devices for Highway Construction, Standard 701321, and as specified herein.

This traffic control standard shall be used for the entire duration of the lane closure allowing for the deck and pavement repairs, latex concrete overlay, and curing time for the latex concrete overlay.

The contractor shall not drive around the outside of the Type III barricades, but shall relocate the barricades temporarily for access. When it is necessary for the barricades to be moved for access, the Contractor shall move the devices into the left lane and/or left shoulder area behind barricades that are to remain in place. At no time shall the barricades be turned parallel to traffic flow for access purposes.

If a path becomes evident around the outside of the barricades, the Contractor shall be required to place additional Type III barricades to prevent driving around the existing barricades.

Additional barricades shall be included in the cost of applicable Traffic Control Standards.

All cost included in conforming with this provision shall be considered a part of TRAFFIC CONTROL AND PROTECTION STANDARD 701321, except the traffic signals will be paid for as one Each for TEMPORARY BRIDGE TRAFFIC SIGNALS, which shall include all signals within the designated work area.

Temporary Rumble Strips: When temporary rumble strips are specified and rumble strips such as self-adhesive rumble strips are used that do not meet the thickness requirement shown on standard 701901, multiple layers of the product shall be used to meet standard 701901.

This work shall be included in the contract unit price per each for TEMPORARY RUMBLE

STRIPS.

TEMPORARY SIGNALS: The Contractor will be required to have someone available at all times to receive phone calls during non-work hours and who is able to reach the job site within one hour of being called. This person will be able to repair the temporary signals or will be able to have flaggers on site within another hour to flag traffic until the signals are again in operation.

Failure to have a person on site within an hour after the initial call out will result in the Contractor being charged a monetary deduction by the Department of One Thousand Dollars ($1,000).

Failure to have traffic restored either with repaired signals or with flaggers within two hours after the initial call out will result in the Contractor being charged monetary deduction by the Department of One Thousand Dollars ($1,000) per hour until traffic is restored. The Contractor may use a traffic control subcontractor for the first call, however this does not relieve the prime Contractor from having a person on call.

Maintenance of Traffic: The traffic shall be maintained using run-arounds as shown on the plans using Traffic Control and Protection Standard 701321.

When the roadway is not closed and/or Standard 701321 are not in effect, the mainline shall be kept open to one-way traffic at all times during working hours and two-way traffic during non-working hours.

Section (115BR)BRR

The Contractor shall notify the Ogle County Highway Department, the corresponding Township Commissioner, city municipality, emergency response agencies (i.e.: fire, ambulance, police), school bus companies and the Department of Transportation (Bureau of Project Implementation) regarding any changes in traffic control.

Bridge work shall be completed using highway Standard 701321 and as detailed in the maintenance of traffic typical section and plans.

Final pavement marking shall be completed using highway Standard 701311.

Two (2) changeable message signs shall be placed on this project two (2) weeks prior to the start of work informing the public of lane closures. Location of the message signs will be determined by the Resident Engineer.

JOINT REPAIR

Description: This work shall consist of furnishing all material, equipment, and labor to remove the existing sealing compound and install a polyurethane sealant with a backing rod at each bridge parapet joint, as shown on the plans, as herein specified and as directed by the Engineer.

Materials: The polyurethane sealant shall be according to Article 1050.04 of the Standard Specifications, and the color shall be grey.

Construction Requirements: Work shall be performed in accordance with Article 503 of the Standard Specifications and as shown on the plans.

Remove existing sealing compound. Existing cork joint filler may also be removed to the dimensions shown on the plans in order to install the proposed 5/8-inch backer rod. Install polyurethane sealant as shown on the plans.

Method of Measurement: Joint repair will be measured for payment in EACH at the locations shown on the contract plans and as directed by the Engineer.

Basis of Payment: The work specified herein, as shown on the plans and directed by the Engineer, shall be paid for the contract unit price for JOINT REPAIR for each parapet joint repair location required.

DIAMOND GRINDING AND SURFACE TESTING BRIDGE SECTIONS

Effective: December 6, 2004 Revised: April 15, 2022

Description. This work shall consist of diamond grinding and surface testing bridge sections.

The bridge section shall consist of the bridge deck plus the bridge approach slab and pavement connector, if present, at each end of the bridge.

Equipment. Equipment shall be according to the following.

Section (115BR)BRR

(a) Diamond Grinder. The diamond grinder shall be a self-propelled planing machine specifically designed for diamond saw grinding. It shall be capable of accurately establishing the profile grade and controlling the grinding cross slope. It shall also have an effective means for removing excess material and slurry from the surface and for preventing dust from escaping into the air. The removal of slurry shall be continuous throughout the grinding operation. The slurry shall be disposed of according to Article 202.03.

The grinding head shall be a minimum of 4 ft. (1.2 m) wide and the diamond saw blades shall be gang mounted on the grinding head at a rate of 50 to 60 blades / ft. (164 to 197 blades/m).

(b) Surface Testing Equipment. Required surface testing and analysis equipment and their jobsite transportation shall be provided by the Contractor. The Profile Testing Device shall be according to Illinois Test Procedure 701 except the trace analysis shall be based on traces from bridge sections.

CONSTRUCTION REQUIREMENTS

General. After all components have been properly cured, the bridge section shall be ground over its entire length and over a width that extends to within 2 ft. (600 mm) of the curbs or parapets.

Grinding shall be done separately before any saw cut grooving, and no concurrent combination of the two operations will be permitted. Whenever possible, each subsequent longitudinal grinding pass shall progress down the cross slope from high to low. The maximum thickness removed shall be 1/4 inch (6 mm); however, when the bridge deck thickness noted on the plans can be maintained, as a minimum, additional removal thickness may be permitted.

The grinding process shall produce a pavement surface that is true in grade and uniform in appearance with longitudinal line-type texture. The line-type texture shall contain corrugations parallel to the outside pavement edge and present a narrow ridge corduroy type appearance. The peaks of the ridges shall be 1/8-inch +/- 1/16-inch (3 mm +/- 1.5 mm) higher than the bottom of the grinding with evenly spaced ridges. It shall be the Contractor’s responsibility to select the actual number of blades per foot (meter) to be used to provide the proper surface finish for the aggregate type and concrete present on the project within the limits specified above.

The vertical difference between longitudinal passes shall be 1/8 inch (3 mm) maximum. The grinding at the ends of the bridge section shall be diminished uniformly at a rate of 1:240 over the pavement connectors.

Grinding shall be continuous through all joints. All expansion joints and bridge components under the joints shall be protected from damage or contact with the grinding slurry.

Surface Testing. The diamond ground bridge section shall be surface tested in the presence of the Engineer prior to opening to traffic.

A copy of the approval letter and recorded settings from the Profile Equipment Verification (PEV) Program shall be submitted to the Engineer prior to testing.

The Contractor shall notify the Engineer a minimum of 24 hours prior to commencement of measurements. All objects and debris shall be removed from the bridge section surface prior to

Section (115BR)BRR testing. During surface testing, joint openings may be temporarily filled with material approved by the Engineer.

Profiles shall be taken in both wheel paths of each lane, 3 ft. (1 m) from, and parallel to, the planned lane lines.

The profile report shall have stationing indicated every 500 ft. (150 m) at a minimum. The profile report shall include the following information: contract number, structure number, beginning and ending stationing, which lane was tested, direction of travel on the trace, date of collection, time of collection, ambient air temperature at time of collection, and the device operator name(s). The data file created from the testing will be submitted to the Engineer and the Bureau of Research for analysis. The file shall be in a format that is compatible with ProVAL software (ERD, PPF).

Trace Reduction and Bump Locating Procedure. All traces shall be reduced using ProVal. This software shall calculate the Mean International Roughness Index (MRI) in inches/mile (mm/km) and indicate any areas of localized roughness in excess of 200 inches/mile (3105 mm/km) on a continuous 25 feet (8 meters) basis.

The average MRI and locations with deviations exceeding the 200 inches/mile (3105 mm/km) limit will be recorded on the Profile Report for Bridge Deck Smoothness.

All ProVAL files shall be provided to the Engineer within two working days of completing the testing. Bureau of Construction Form BC 2450 shall be provided to the Engineer. An example Form BC 2450 is attached. All files shall contain serial numbers for the vehicle and profiling equipment, the approved settings from the PEV program. The Engineer will compare these settings with the approved settings from the PEV Program. If the settings do not match, the results will be rejected and the section shall be retested/reanalyzed with the appropriate settings.

Corrective Actions. Within the bridge section, all deviations in excess of 200 inches/mile (1575

mm) within any continuous length of 25 ft. (8 m) shall be corrected. Correction of deviations shall not result in the deck thickness being less than the minimum. Where corrective work is performed, the bridge section shall be retested to verify that corrections have produced a MRI of 200 inch/mile (3105 mm/km) within an continuous length of 25 ft (8 m) or less for each lane. The Contractor shall furnish and Form BC 2450 the ProVAL files to the Engineer and the Bureau of Research within two working days after any corrections are made.

Corrective actions shall be performed at no additional cost to the department.

The Engineer may perform profile testing on the surface at any time for monitoring and comparison purposes.

Method of Measurement. This work will be measured for payment in place and the area computed in square yards (square meters) of diamond grinding performed.

Basis of Payment. This work will be paid for at the contract unit price per square yard (square meter) for DIAMOND GRINDING (BRIDGE SECTION).

Section (115BR)BRR

Instructions for Completing Bridge Deck Smoothness Assessment Summary ALR

This form shall be prepared and submitted, along with the raw data files, to the Engineer.

Report Type:

Initial – Testing of bridge section prior to any smoothness grinding.

Intermediate – After initial pass of smoothness grinding has been completed.

Final – All smoothness grinding has been completed.

Other information:

Submission Date – Date in which it has been submitted to the Engineer

Project Type – New Deck, Microsilica Overlay, Latex Overlay, Fly Ash Overlay

Specification Effective Date – revision date of the specification in the contract

Begin ALR Section 1 – beginning station of ALR finding

End ALR Section 1 – end station of ALR finding

Distance – End ALR minus the Begin ALR station number

MRI – The value of the ALR at that location.

Section (115BR)BRR

Section (115BR)BRR

BRIDGE DECK GROOVING (LONGITUDINAL)

Effective: December 29, 2014 Revised: March 29, 2017

Revise Article 503.16(a)(3)b. to read as follows.

b. Saw Cut Grooving. The grooving operation shall not be started until after the expiration of the required curing or protection period and after correcting excessive variations by grinding or cutting has been completed.

The grooves shall be cut into the hardened concrete, parallel to the centerline of the roadway, using a mechanical saw device equipped with diamond blades that will leave grooves 1/8 in. wide and 3/16 in. ± 1/16 in. deep (3 mm wide and 5 mm ± 1.5 mm deep), with a uniform spacing of 3/4

in. ± 1/16 in. (20 mm ± 1.5 mm) centers. The grooving shall typically extend the full width of the traffic lanes and terminate at the edge of the traffic lane or shoulder. If the bridge has a variable width traffic lane, the grooving shall remain parallel to the centerline of the main roadway. Any staggering of the groove terminations to accommodate the variable width shall be within the shoulders. Grooves shall not be cut closer than 3 inches (75 mm) nor further than 6 inches (150

mm) from any construction joint running parallel to the grooving. In addition, grooves shall not be cut within 6 in. ± 1 in. (150 mm ± 25 mm) from deck drains and expansion joints.

The grooving machine shall contain diamond blades mounted on a multi-blade arbor on a self-propelled machine built for grooving hardened concrete surfaces. The grooving machine shall have a depth control device that detects variations in the deck surface and adjusts the cutting head height to maintain a specified depth of groove. The grooving machine shall have a guide device to control multi-pass alignment.

The removal of slurry shall be continuous throughout the grooving operations. The grooving equipment shall be equipped with vacuum slurry pickup equipment which shall continuously pick up water and sawing dust, and pump the slurry to a collection tank. The slurry shall be disposed of offsite according to Article 202.03.

Cleanup shall be continuous throughout the grooving operation. All grooved areas of the deck shall be flushed with water as soon as possible to remove any slurry material not collected by the vacuum pickup. Flushing shall be continued until all surfaces are clean.

Method of Measurement. This work shall be measured for payment according to Article 503.21(b) except no measurement will be made for any grooving of the shoulders to accommodate a variable width traffic lane.

Basis of Payment. This work will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK GROOVING (LONGITUDINAL).

Section (115BR)BRR

AUTOMATED FLAGGER ASSISTANCE DEVICES (BDE)

Effective: January 1, 2008 Revised: April 1, 2023

Description. This work shall consist of furnishing and operating automated flagger assistance devices (AFADs) as part of the work zone traffic control and protection for two-lane highways where two-way traffic is maintained over one lane of pavement in segments where no sideroads or entrances require deployment of additional flaggers. Use of these devices shall be at the option of the Contractor.

Equipment. AFADs shall be the STOP/SLOW or Red/Yellow Lens type mounted on a trailer or moveable cart meeting the requirements of the MUTCD and NCHRP 350 or MASH 2016, Category 4.

General. AFADs shall be placed at each end of the traffic control, where a flagger is shown on the plans. The AFAD shall be setup within five degrees of vertical.

Flagger symbol signs as shown on the plans shall be replaced with “BE PREPARED TO STOP” signs when the AFAD is in operation.

Personal communication devices shall not be used to operate the AFAD.

Flagging Requirements. Flaggers and flagging requirements shall be according to Article 701.13 of the Standard Specifications and the following.

Each AFAD shall be operated by a flagger trained to operate the specific AFAD to be deployed.

A minimum of two flaggers shall be on site at all times during operation. Each flagger shall be positioned outside the lane of traffic and near each AFAD’s location.

Flagging equipment required for traditional flagging shall be available near each AFAD location in the event of AFAD equipment malfunction/failure.

For nighttime flagging, the AFAD and flagger shall be illuminated according to Article 701.13 of the Standard Specifications.

When not in use, AFADs will be considered non-operating equipment and shall be stored according to Article 701.11 of the Standard Specifications.

Basis of Payment. This work will not be paid for separately but shall be considered as included in the cost of the various traffic control items included in the contract.

Section (115BR)BRR

BRIDGE DECK CONCRETE OVERLAYS

Effective: January 1, 2026

Add the following Section 531 to the Standard Specifications:

“SECTION 531. BRIDGE DECK CONCRETE OVERLAYS

531.01 Description. This work shall consist of constructing a concrete overlay on an existing concrete bridge deck or approach slab.

531.02 Materials. Materials shall be according to the following.

Item................................................................................................. Article/Section

(a) Coarse Aggregate (Note 1) .................................................................................. 1004.02

(b) Packaged, Dry, Rapid Hardening Mortar or Concrete

(c) Portland Cement Concrete (Note 2) (Note 3)

(d) Fibers for Concrete (Note 4)

Note 1. Coarse aggregate shall be crushed stone or crushed gravel.

Note 2. Concrete shall be Class BS with the following exceptions.

Overlay Type Gradation Fly Ash Ground Granulated Blast Furnace (GGBF) Slag High Reactivity Metakaolin (HRM) Microsilica

CA 11, CA 13, CA 14, or CA 16

Latex CA 13, CA 14, or CA 16

Slump shall be 2-7 in. (50-175 mm). For latex overlays, the maximum slump may be increased if no visible segregation is observed.

For latex overlays, air content shall be a maximum of 7.0 percent and maximum water/cement ratio shall be 0.40.

For Class F fly ash overlays, fly ash shall replace cement at the maximum rate permitted according to Article 1020.05(c)(1)b. The replacement ratio shall be 1:1.

For Class C fly ash overlays, fly ash shall replace cement at a rate ranging from a minimum of 25 percent to the maximum rate permitted according to Article 1020.05(c)(1)c. The replacement ratio shall be 1:1.

For GGBF slag overlays, GGBF slag shall replace cement at a rate ranging from a minimum of 25 percent to the maximum rate permitted according to Article 1020.05(c)(2)b.

The replacement ratio shall be 1:1.

For microsilica and HRM overlays, the cementitious factor (excluding microsilica or HRM) shall be 565 lb/cu yd (390 kg/cu m). The minimum amount of microsilica or HRM added to the mix shall be 33 lb/cu yd (20 kg/cu m) and the maximum shall be 37 lb/cu yd (22 kg/cu m).

Section (115BR)BRR

For latex overlays, the cementitious factor shall be a minimum of 658 lbs/cu yd (335 kg/cu m), the dosage of the latex admixture shall be 24.5 gal/cu yd (121.3 L/cu m), the coarse aggregate shall be 42-50 percent by weight (mass) of total aggregate, no air entraining admixture shall be used, and water used shall be a maximum of 157 lb/cu yd (93.1 kg/cu m) (including free moisture on the fine and coarse aggregates).

Note 3. For HRM and microsilica overlays, the Contractor shall submit a specific batching sequence for verification by the Engineer. The submittal shall include whether a truck or stationary mixer will be used. For HRM overlays, the submittal shall include whether bulk or bagged HRM will be used. For microsilica overlays, the submittal shall include whether the microsilica to be used is a water based slurry, bulk densified, or bagged densified.

Note 4. Synthetic fibers, when required, shall be according to Article 1014.01, and 1014.04 or 1014.05, as applicable.

531.03 Equipment. Equipment shall be according to the following.

Item................................................................................................. Article/Section

(a) Concrete Equipment (Note 1) .............................................................................. 1020.03

(b) Finishing Equipment .............................................................................................. 503.03

(c) Fogging Equipment ......................................................................................... 1103.17(k)

(d) Mechanical Scarifying Equipment (Note 2) .......................................................... 1101.16

(e) Hydro-Scarification Equipment (Note 3)

(f) Hand-Held Blast Cleaning Equipment (Note 4)

(g) Mechanical Blast Cleaning Equipment (Note 5)

(h) Pull-Off Test Equipment (Note 6)

Note 1. For latex concrete overlays, a mobile portland cement concrete plant shall be used according to Articles 1020.12 and 1103.04.

Note 2. Mechanical scarifying equipment shall be capable of uniformly scarifying or removing the old concrete surface and new patches to the depth required. The minimum width of the equipment shall be 3 ft (1 m).

Note 3. Hydro-scarification equipment shall consist of filtering and pumping units operating with a computerized, self-propelled robotic machine capable of removing sound concrete in a single pass to the specified depth and operating at a 16,000 psi (110 MPa) minimum water pressure with a 55 gal/min (208 L/min) minimum water flow rate.

Note 4. Hand-held blast cleaning shall be performed by high-pressure waterblasting or abrasive blasting. High-pressure waterblasting equipment shall have a minimum water pressure of 7000 psi (48 MPa) and have oil traps.

Note 5. Mechanical blast cleaning shall be performed by high-pressure waterblasting or shotblasting capable of removing weak concrete at the surface, including the microfractured concrete surface layer remaining as a result of mechanical scarification, and shall have oil traps.

Mechanical high-pressure waterblasting equipment shall be mounted on a wheeled carriage, include multiple nozzles mounted on a rotating assembly, and shall be operated

Section (115BR)BRR with a 7000 psi (48 MPa) minimum water pressure. The distance between the nozzles and the deck surface shall be kept constant and the wheels shall maintain contact with the deck surface during operation.

Note 6. Equipment used to perform pull-off testing shall be on the Department’s qualified product list “Pull-Off Test Equipment for Bridge Deck Overlays”.

CONSTRUCTION REQUIREMENTS

531.04 General. The Contractor shall control the runoff water generated by the various construction activities in such a manner as to minimize, to the maximum extent practicable, the discharge of untreated effluent into adjacent waters, and shall properly dispose of the solids generated according to Article 202.03. The Contractor shall submit a water management plan to the Engineer specifying the control measures to be used. The control measures shall be in place prior to the start of runoff water generating activities. Runoff water shall not be allowed to constitute a hazard to adjacent or underlying roadways, waterways, drainage areas or railroads nor be allowed to erode existing slopes.

531.05 Preparation. Sidewalks, curbs, drains, reinforcement, existing transverse and longitudinal joints, and other appurtenances which are to remain in place shall be protected from damage during scarification and cleaning operations.

(a) Scarification. The scarification shall consist of removing the concrete using mechanical and hydro-scarifying equipment to the depth specified on the plans. The depth specified shall be measured from the existing concrete surface to the grout line between aggregates remaining after scarification. Power-driven hand tools shall be used for removal around areas to remain in place and areas not accessible to the scarifying equipment. Power-driven hand tools include jackhammers lighter than the nominal 45 lb (20 kg) class.

Jackhammers or chipping hammers shall be operated at an angle less than 45 degrees measured from the surface of the slab.

Mechanical scarification equipment shall be used to remove the initial 1/4 in. (25 mm) minimum depth of concrete, creating a uniform roughened concrete surface. If the Contractor’s use of mechanical scarifying equipment results in exposing, snagging, or dislodging the top mat of reinforcing steel, the mechanical scarifying depth shall be reduced as necessary immediately. If the exposing, snagging, or dislodging the top mat of reinforcing steel cannot be avoided, the mechanical scarifying shall be stopped immediately and the remaining removal shall be accomplished using the hydro-scarification equipment. All damage to the existing reinforcement resulting from the Contractor’s operation shall be repaired or replaced at no additional cost to the Department. Replacement shall include the removal of any additional concrete required to position or splice the new reinforcing steel. Undercutting of exposed reinforcement bars shall only be as required to replace or repair damaged reinforcement. Repairs to existing reinforcement shall be according to Section 530.

(b) Sounding. Just prior to performing hydro-scarification, the deck shall be sounded, with unsound areas marked on the deck by the Engineer. A trial section, in an area of sound concrete, on the existing deck surface will be designated by the Engineer to calibrate the equipment settings to remove sound concrete to the required depth, in a single pass, and provide a highly roughened bondable surface. The trial section shall consist of approximately 30 sq ft (3 sq m). After calibration in an area of sound concrete, the

Section (115BR)BRR equipment shall be moved to a second trial section, as designated by the Engineer, in an area containing unsound concrete to verify the calibrated settings are sufficient to remove the unsound concrete. If the calibrated settings are insufficient to remove the unsound concrete, the equipment may be moved back to an area of sound concrete and the calibration settings verified.

After the equipment settings are established, they shall be supplied to the Engineer and include the following.

(1) Water pressure

(2) Water flow rate

(3) Nozzle type and size

(4) Nozzle travel speed

(5) Machine staging control (step/advance rate)

Hydro-scarification may begin after the calibration settings have been approved by the Engineer. At least the last 1/2 in. (13 mm) of removal shall be accomplished with hydro-scarification equipment.

The removal depth will be verified by the Engineer. If sound concrete is being removed below the desired depth, the equipment shall be recalibrated.

(c) Cleaning. After hydro-scarification, the concrete shall be vacuum cleaned before the water and debris are allowed to dry and re-solidify to the deck. The vacuum shall be equipped with fugitive dust control devices capable of removing wet debris and water in the same pass. The vacuum shall also be capable of washing the deck with pressurized water prior to the vacuum operation to dislodge all debris and slurry from the deck surface.

The use of alternative cleaning and debris removal methods to minimize driving heavy vacuum equipment over the exposed reinforcement may be used subject to the approval of the Engineer.

531.06 Patching. After scarification and cleaning, the Engineer will sound the scarified concrete and survey the existing reinforcement condition. All remaining unsound concrete and unacceptably corroded reinforcement bars will be marked for additional removal and/or repairs and shall be completed according to Section 530 except as noted below.

In areas where unsound concrete extends below the specified removal depth and hydro-scarification completely removes unsound concrete, a full-depth repair shall be required when the bottom mat of reinforcement is exposed.

Full-depth patches shall be struck off to the scarified surface and then roughened with a suitable stiff bristled broom or wire brush to provide a rough texture. Hand finishing of the patch surface shall be kept to a minimum to prevent overworking of the surface.

Any removal required or made below the specified depth for scarification, which does not result in full-depth repair, shall be filled with the overlay material at the time of the overlay placement.

Undercutting of exposed reinforcement bars shall only be as required to replace or repair damaged or corroded reinforcement, or to perform a full depth repair.

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531.07 Final Surface Preparation. Final surface preparation shall include the cleaning of all dust, debris, concrete fines, and other foreign substances from the surface including vertical faces of curbs, previously placed adjacent overlays, barrier walls up to a height of 1 in. (25 mm) above the overlay, depressions, and beneath reinforcement bars using hand-held blast cleaning methods.

If spoils from the scarification operation are allowed to dry and re-solidify on the surface, the surface shall be cleaned with mechanical blast cleaning equipment. Areas determined by the Engineer to be inaccessible to scarifying equipment shall be blast cleaned with hand-held equipment.

The Engineer may require surface pull-off testing of areas inaccessible to scarifying equipment. The Contractor shall provide the testing equipment in accordance with Illinois Test Procedure 304 “Pull-Off Test (Surface Method)”. Prior to the start of testing, the Contractor shall submit to the Engineer a technical data sheet and material safety data sheet for the epoxy used to perform the testing. For solvents used to clean the equipment, a material safety data sheet shall be submitted. The Engineer will determine each test location, and each individual test shall have a minimum strength of 175 psi (1,207 kPa). In the case of a failing test, the Contractor shall adjust the blast cleaning method and re-clean the area. Testing will be repeated until satisfactory results are attained.

Exposed reinforcement bars shall be free of dirt, detrimental scale, paint, oil, and other foreign substances which may reduce bond with the concrete. Loose, scaling rust shall be removed by rubbing with burlap, wire brushing, blast cleaning, or another method approved by the Engineer.

Loose reinforcement bars, as determined by the Engineer, shall be retied.

Dust, concrete fines, debris, and water resulting from the surface preparation shall be confined and immediately removed. If concrete placement does not follow immediately after the final cleaning, the area shall be protected with anchored white polyethylene sheeting.

531.08 Equipment Preparation. Before placing the overlay, the finishing machine shall be operated over the full length of bridge segment to be overlaid to check support rails for deflection and confirm the minimum overlay thickness. If adjustments are needed, another check shall be performed.

531.09 Placing. Concrete placement shall be according to Article 503.07, 503.16, and the following.

The surface shall be cleaned to the satisfaction of the Engineer and shall be thoroughly wetted and maintained in a dampened condition with water for at least 12 hours before placement of the overlay. Excess water shall be removed by compressed air or by vacuuming prior to the beginning of overlay placement. Water shall not be applied to the surface within one hour before or at any time during placement of the overlay.

Internal vibration shall be performed along edges, adjacent to bulkheads, and where the overlay thickness exceeds 3 in. (75 mm). Internal vibration along the longitudinal edges of a pour shall be performed with a minimum of two hand-held vibrators, one on each edge of the pour.

Hand finishing shall be performed along the edges of the pour from sidewalks, curbs, or work bridges.

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A construction dam or bulkhead shall be installed in case of a delay of 30 minutes or more in the concrete placement operation.

Construction joints shall be formed. When required by the Engineer, the previously placed overlay shall be sawed full-depth to a straight and vertical edge before fresh concrete is placed.

The Engineer will determine the extent of the removal. When longitudinal joints are not shown on the plans, the locations shall be subject to approval by the Engineer and shall not be located in the wheel paths.

The Contractor shall stencil the date of construction (month and year) and the appropriate letters into the overlay before it takes its final set, as follows.

(a) MS, for MicroSilica

(b) MSFA, when fly ash is used in the silica fume mix design, for MicroSilica Fly Ash

(c) MSF, for MicroSilica with Fibers

(d) MSFAF, when fly ash is used in the silica fume mix design, for MicroSilica Fly Ash with

Fibers

(e) LX, for LateX

(f) LXF, for LateX with Fibers

(g) HRM, for High-Reactivity Metakaolin

(h) HRMFA, when fly ash is used in the HRM mix design, for High-Reactivity Metakaolin Fly

Ash

(i) HRMF, for High-Reactivity Metakaolin with Fibers

(j) HRMFAF, when fly ash is used in the HRM mix design, for High-Reactivity Metakaolin Fly

Ash with Fibers

(k) FA, for Fly Ash

(l) FAF, for Fly Ash with Fibers

(m) GGBF, for Ground Granulated Blast Furnace slag

(n) GGBFF, for Ground Granulated Blast Furnace slag with Fibers

The stencil shall be in a noticeable location, as determined by the Engineer, for each stage of construction outside of the grooving where possible and within 3 ft (1 m) of an abutment joint.

The characters shall be 3 to 4 in. (75 to 100 mm) in height, 1/4 in. (5 mm) in depth and face the centerline of the roadway.

531.10 Weather and Other Limitations. Temperature control for concrete placement shall be according to Article 1020.14(b). The concrete protection from low air temperatures during the curing period shall be according to Article 1020.13(d). Concrete shall not be placed when rain is expected during the working period. If night placement is required, illumination and placement procedures will be subject to approval by the Engineer.

Concrete delivery vehicles driven on the structure shall be limited to a maximum load of

6 cu yd (4.6 cu m).

Truck mixers, concrete pumps, or other heavy equipment will not be permitted on any portion where the top reinforcing mat has been exposed. Conveyors, buggy ramps, and pump piping shall be installed in a way that will not displace undercut reinforcement bars. Air compressors may be operated on the deck only if located directly over a pier and supported off undercut reinforcement bars. Compressors will not be allowed to travel over undercut reinforcement bars.

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Concrete removal may proceed during final cleaning and concrete placement on adjacent portions, provided the removal does not interfere with the cleaning or placement operations.

Water or contaminants from the hydro-scarification shall not be permitted in areas where the new overlay has been placed until the overlay has cured a minimum of 24 hours.

No concrete shall be removed within 6 ft (1.8 m) of a newly-placed overlay until the concrete has obtained a minimum compressive strength of 3000 psi (20,700 kPa) or flexural strength of 600 psi (4,150 kPa).

531.11 Curing. For silica fume, HRM, GGBF, and fly ash concrete overlays, the surface shall be continuously wet cured for at least seven days according to Articles 1020.13(a)(5) or (a)(6).

For latex modified concrete overlays, the surface shall be continuously wet cured for at least

48 hours according to Articles 1020.13(a)(3), (a)(5), or (a)(6). After the wet cure is completed, all layers of covering materials shall be removed to allow for a dry cure for at least 48 hours. If the ambient temperature falls below 45°F (10°C) during either the wet or dry curing periods, the time below 45°F (10°C) will not be included in the 96 hour curing period. If there is sufficient rain to wet the surface of the overlay for more than one hour of the dry cure period, the wet time will not be included in the 48 hour dry cure period.

When the mats or blankets have been pre-dampened, excess water shall not be allowed to drip onto the overlay during placement.

531.12 Testing. The Engineer reserves the right to conduct pull-off tests on the overlay to determine if any areas are not bonded to the underlying concrete. The overlay will be tested according to the Illinois Test Procedure 305 “Pull-Off Test (Overlay Method)”, and the Contractor shall provide the test equipment. Prior to the start of testing, the Contractor shall submit to the Engineer a technical data sheet and material safety data sheet for the epoxy used to perform the testing. For solvents used to clean the equipment, a material safety data sheet shall be submitted.

Each individual test shall have a minimum strength of 150 psi (1,034 kPa). If the test results are unacceptable, the overlay shall be removed and replaced at the locations determined by the Engineer. When removing portions of an overlay, the saw cut shall be a minimum depth of 1 in.

(25 mm).

If the overlay is to remain in place, all core holes due to testing shall be filled with a rapid set mortar or concrete. Only enough water to permit placement and consolidation by rodding shall be used, and the material shall be struck-off flush with the adjacent material.

For a rapid set mortar mixture, one part packaged rapid set cement shall be combined with two parts fine aggregate, by volume; or a packaged rapid set mortar shall be used. For a rapid set concrete mixture, a packaged rapid set mortar shall be combined with coarse aggregate according to the manufacturer’s instructions; or a packaged rapid set concrete shall be used.

Mixing of a rapid set mortar or concrete shall be according to the manufacturer’s instructions.

531.13 Opening to Traffic. No traffic or construction equipment will be permitted on the overlay until after the cure period and the concrete has obtained a minimum compressive strength of 4000 psi (27,500 kPa) or flexural strength of 675 psi (4,650 kPa).

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531.14 Method of Measurement. Scarification will be measured for payment in square yards (square meters). No additional payment will be made for multiple passes of the equipment.

The concrete overlay will be measured for payment in square yards (square meters).

Additional concrete placed with the overlay, required to fill all depressions below the specified thickness will be measured for payment in cubic yards (cubic meters). The volume will be determined by subtracting the theoretical volume of the overlay from the ticketed volume of overlay delivered minus the volume estimated by the Engineer left in the last truck at the end of the overlay placement. The theoretical cubic yard (cubic meter) quantity for the overlay will be determined by multiplying the plan surface area of the overlay times the specified thickness of the overlay.

Partial depth removal in concurrence with hydro-scarification will not be measured for payment.

531.15 Basis of Payment. Scarification will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK SCARIFICATION, of the depth specified.

Silica fume concrete overlay will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK MICROSILICA CONCRETE OVERLAY, of the thickness specified.

Latex modified concrete overlay will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK LATEX CONCRETE OVERLAY, of the thickness specified. HRM concrete overlay will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK HRM CONCRETE OVERLAY, of the thickness specified. GGBF or fly ash concrete overlay will be paid for at the contract unit price per square yard (square meter) for BRIDGE DECK GGBF OR FLY ASH CONCRETE OVERLAY, of the thickness specified.

The additional volume of overlay required to fill all depressions below the specified thickness and/or for grade adjustments will be paid for at the Contractor’s actual…