IDOT 64T47-048.pdf

Letting June 12, 2026

Notice to Bidders, Specifications and Proposal

Contract No. 64T47 OGLE County Section (102BR-1)BRR Route FAP 17A Project STP-IQ9D(389) 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. 64T47 OGLE County Section (102BR-1)BRR Project STP-IQ9D(389) Route FAP 17A District 2 Construction Funds

Bridge repairs, deck overlay and joint replacement on SN 071-0078, carrying IL 64 over Pine Creek, 4.1 miles east of IL 26.

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 17A (IL 64)

Section (102BR-1)BRR

Ogle 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 (102BR-1)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 (102BR-1)BRR i

TABLE OF CONTENTS

LOCATION OF PROJECT

DESCRIPTION OF PROJECT

TRAFFIC CONTROL PLAN

JOINT REPAIR

PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR

DIAMOND GRINDING AND SURFACE TESTING BRIDGE SECTIONS

BRIDGE DECK GROOVING (LONGITUDINAL)

PREFORMED BRIDGE JOINT SEAL

BAR SPLICERS, HEADED REINFORCEMENT

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)

VEHICLE AND EQUIPMENT WARNING LIGHTS (BDE)

Section (102BR-1)BRR ii

WORK ZONE TRAFFIC CONTROL DEVICES (BDE)

WORKING DAYS (BDE)

Section (102BR-1)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 17A (IL 64), Project STP-IQ9D(389), Section (102BR-1)BRR, Ogle County, Contract No. 64T47 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 071-0078 over Pine Creek is located on Illinois Route 64, 4.1 Miles east of Illinois Route 26 in Mount Morris Township. The project is located in Ogle County, Illinois.

DESCRIPTION OF PROJECT

The work on this project consists of ¾” bridge deck and approach slab scarification, installation of 2 ¼” bridge latex concrete overlay, bridge deck and approach 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 (102BR-1)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 (102BR-1)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 (102BR-1)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.

PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR

Effective: May 14, 2020

Description This work shall consist of repairing precast prestressed concrete (PPC) I-beams along with all necessary hardware, labor and equipment in accordance with the Plans and as directed by the Engineer.

Section (102BR-1)BRR

Materials Materials shall be according to the following:

Item Article/Section

(a) Portland Cement Concrete (Note 1) …………………………………..…………1020

(b) Non-shrink Grout (Note 2) .…………………………………………………….1024.02

(c) Shotcrete (High Performance) (Notes 3 and 4)

Note 1. The concrete shall meet all the requirements specified in Section 1020 of the

Standard Specifications for Class PS Concrete for precast prestressed concrete members, except the maximum size of the aggregate shall be 1

2″.

Note 2. The grout shall meet all the requirements specified in Section 1024.02 of the

Standard Specifications for Non-Shrink Grout, except coarse aggregate with a maximum size of ⅜” shall be added with the amount as specified by the manufacturer. The product shall be selected from the “Approved List of Non- Shrink Grouts” maintained by the Department. The repair material chosen shall be appropriate for the thickness of repair to be made.

Note 3. Packaged shotcrete that includes aggregate shall be from the Department’s approved list of Packaged High-Performance Shotcrete, and independent laboratory test results showing the product meets Department specifications will be required. The product shall be a packaged, pre-blended, and dry combination of materials, for the wet-mix shotcrete method according to ASTM C 1480. A nonchloride accelerator may be used according to the shotcrete manufacturer’s recommendations. The shotcrete shall be Type FA or CA, Grade FR, and Class I. The fibers shall be Type III synthetic according to ASTM C 1116.

The packaged shotcrete shall have a water-soluble chloride ion content of less than 0.40 lb/cu yd (0.24 kg/cu m). The test shall be performed according to ASTM C 1218, and the hardened shotcrete shall have an age of 28 to 42 days at the time of test. The ASTM C 1218 test shall be performed by an independent lab a minimum of once every two years, and the test results shall be provided to the Department.

Each individual aggregate used in the packaged shotcrete shall have either a maximum ASTM C 1260 expansion of 0.16 percent or a maximum ASTM C 1293 expansion of 0.040 percent. However, the ASTM C 1260 value may be increased to 0.27 percent for each individual aggregate if the cement total equivalent alkali content (Na2O + 0.658K2O) does not exceed 0.60 percent.

As an alternative to these requirements, ASTM C 1567 testing which shows the packaged shotcrete has a maximum expansion of 0.16 percent may be submitted. The ASTM C 1260, C 1293, or C 1567 test shall be performed a minimum of once every two years.

The 7 and 28-day compressive strength requirements in ASTM C 1480 shall not apply. Instead the shotcrete shall obtain a minimum compressive strength of 4000 psi (27,500 kPa) at 14 days.

Section (102BR-1)BRR

The packaged shotcrete shall be limited to the following proportions:

The portland cement and finely divided minerals shall be 6.05 cwt/cu yd (360 kg/cu m) to 8.50 cwt/cu yd (505 kg/cu m) for Type FA and 6.05 cwt/cu yd (360 kg/cu. m) to 7.50 cwt/cu yd (445 kg/cu m) for Type CA. The portland cement shall not be below 4.70 cwt/cu yd (279 kg/cu m) for Type FA or CA.

The finely divided mineral(s) shall constitute a maximum of 35 percent of the total cement plus finely divided mineral(s).

Class F fly ash is optional and the maximum shall be 20 percent by weight

(mass) of cement.

Class C fly ash is optional and the maximum shall be 25 percent by weight

(mass) of cement.

Ground granulated blast-furnace slag is optional and the maximum shall be 30 percent by weight (mass) of cement.

Microsilica is required and shall be a minimum of 5 percent by weight (mass) of cement, and a maximum of 10 percent. As an alternative to microsilica, high reactivity metakaolin may be used at a minimum of 5 percent by weight (mass) of cement, and a maximum of 10 percent.

Fly ash shall not be used in combination with ground granulated blast-furnace slag. Class F fly ash shall not be used in combination with Class C fly ash.

Microsilica shall not be used in combination with high-reactivity metakaolin. A finely divided mineral shall not be used in combination with a blended hydraulic cement, except for microsilica or high-reactivity metakaolin.

The water/cement ratio as defined in Article 1020.06 shall be a maximum of

0.42.

The air content as shot shall be 4.0 – 8.0 percent.

Note 4 Packaged shotcrete that does not include pre-blended aggregate shall be from the Department’s approved list of Packaged High-Performance Shotcrete, and independent laboratory test results showing the product meets Department specifications will be required. The shotcrete shall be according to Note 3, except the added aggregate shall be according to Articles 1003.02 and

1004.02 in addition to each individual aggregate meeting the maximum expansion requirements of Note 3. The aggregate gradation shall be according to the manufacturer. The shotcrete shall be batched and mixed with added aggregate according to the manufacturer.

Section (102BR-1)BRR

Equipment Equipment shall be according to Article 503.03 and the following.

Chipping Hammer – The chipping hammer for removing concrete shall be a light-duty pneumatic or electric tool with a 15 lb. (7 kg) maximum class or less.

Blast Cleaning Equipment – Blast cleaning equipment for concrete surface preparation shall be the abrasive type, and the equipment shall have oil traps.

High Performance Shotcrete Equipment – The batching, mixing, pumping, hose, nozzle, and auxiliary equipment shall be for the wet-mix shotcrete method and shall meet the requirements of

ACI 506R.

Construction Requirements PPC I-beam repairs shall be done before addition of new concrete, but after removal of any existing concrete

Bottom Flange Repair:

The damaged area of the beams shall be cleaned of all loose and spalled concrete, and sealant.

All loose material shall be removed to sound concrete until coarse aggregate will break under chipping rather than dislodging. Hand tools shall be used for the removal of concrete adjacent to prestressing strands. While a 15-pound chipping hammer may be used away from prestressing strands, extreme care shall be used not to damage the exposed prestressing strands.

Using the same tools, remove the existing concrete to sound concrete along the edges of the damaged areas to a depth of 1″ min. to 11

2″ max. The edges shall be saw cut 3 4″ deep or less.

The limits of removal on the beam are shown in the details. The entire area of existing concrete against which new concrete will be placed and any exposed portions of the prestressing strands shall be sandblasted. The concrete shall be sandblasted to expose clean, well-bonded aggregate.

All surfaces of the existing concrete in the areas to be repaired shall be prepared in accordance with Art. 503.09 (b) of the Standard Specs. The concrete beam to be repaired must be at a temperature of at least 50 °F or higher.

Self-drilling anchors or power-driven pins as shown in the Plans shall be placed at 9″ alternate centers horizontally and located vertically 3″ and 7″ up from the bottom of the beam. Use wire ties in areas where the strands are exposed as shown in the details. Place 1″ x 1″ x 18 gage welded wire fabric in repair areas and attach it to the pins or strands with wire ties. The clearance between the finished surface of the new concrete and the welded wire fabric shall be 1″ minimum.

The beam involved in this work shall be rebuilt to its original dimensions.

Place the lower form on the bottom of the beam and compact by vibrating (or other approved methods) the concrete mix into the voids. After accessible voids have been filled and compacted, the top vertical form shall be raised into position and the remaining voids filled and compacted.

The sloping upper surface shall be finished to the configuration of the existing PPC I-Beam flange.

Section (102BR-1)BRR

Web and Top Flange Repair:

The damaged area of the beams shall be cleaned of all loose and spalled concrete, and sealant.

All loose material shall be removed to sound concrete until coarse aggregate will break under chipping rather than dislodging.

The edges shall be saw cut 34″ deep or less. The limits of removal on the beam are shown in the details. The entire area of existing concrete against which new concrete will be placed and any exposed portions of the reinforcement bars shall be sandblasted. The concrete shall be sandblasted to expose clean, well-bonded aggregate.

All surfaces of the existing concrete in the areas to be repaired shall be prepared in accordance with Art. 503.09 (b) of the Standard Specs. The concrete beam to be repaired must be at a temperature of at least 50 °F or higher.

The beam involved in this work shall be finished to the configuration of the existing PPC I-Beam web.

Construction Repair Methods All repair areas shall be inspected and approved by the Engineer prior to placement of the concrete/grout or application of the shotcrete.

(a) Formed Concrete Repair. Falsework shall be according to Article 503.05. Forms shall be according to Article 503.06. Formwork shall provide a smooth and uniform concrete finish, and shall approximately match the existing concrete structure. Formwork shall be mortar tight and closely fitted where they adjoin the existing concrete surface to prevent leakage. Air vents may be provided to reduce voids and improve surface appearance.

The Contractor may use exterior mechanical vibration, as approved by the Engineer, to release air pockets that may be entrapped.

The concrete shall be placed and consolidated according to Article 503.07. The concrete shall not be placed when frost is present on the surface of the repair area, or the surface temperature of the repair area is less than 40 °F (4 °C). All repaired members shall be restored as close as practicable to their original dimensions.

Curing shall be done according to Article 1020.13.

If temperatures below 45°F (7°C) are forecast during the curing period, protection methods shall be used. Protection Method I according to Article 1020.13(d)(1), or Protection Method II according to Article 1020.13(d)(2) shall be used during the curing period.

The surfaces of the completed repair shall be finished according to Article 503.15.

(b) Non-Shrink Grout. Mix and place the non-shrink grout according to the manufacturer’s instructions. The grout shall be placed and finished to the contours of the member, as originally constructed.

Section (102BR-1)BRR

The grout shall not be placed when the air temperature is below 45 °F (7 °C) and falling or below 40 °F (4 °C). Grout shall not be placed when the air temperature is greater than 90 °F (32 °C). The grout shall have a minimum temperature of 50 °F (10 °C) and a maximum temperature of 90 °F (32 °C). The grout shall not be applied during periods of rain unless protective covers or enclosures are installed. The grout shall not be applied when frost is present on the surface of the repair area, or the surface temperature of the repair area is less than 40 °F (4 °C).

(c) Shotcrete. Shotcrete shall be tested by the Engineer for air content according to Illinois Modified AASHTO T 152. The sample shall be obtained from the discharge end of the nozzle by shooting a pile large enough to scoop a representative amount for filling the air meter measuring bowl. Shotcrete shall not be shot directly into the measuring bowl for testing.

For compressive strength of shotcrete, an 18 x 18 x 3.5 in. (457 x 457 x 89 mm) test panel shall be shot by the Contractor for testing by the Engineer. A steel form test panel shall have a minimum thickness of 3/16 in. (5 mm) for the bottom and sides. A wood form test panel shall have a minimum 3/4 in. (19 mm) thick bottom, and a minimum 1.5

in. (38 mm) thickness for the sides. The test panel shall be cured according to Article

1020.13 (a) (3) or (5) while stored at the jobsite and during delivery to the laboratory.

After delivery to the laboratory for testing, curing and testing shall be according to ASTM C 1140.

The method of alignment control (i.e. ground wires, guide strips, depth gages, depth probes, and formwork) to ensure the specified shotcrete thickness and reinforcing bar cover is obtained shall be according to ACI 506R. Ground wires shall be removed after completion of cutting operations. Guide strips and formwork shall be of dimensions and a configuration that do not prevent proper application of shotcrete. Metal depth gauges shall be cut 1/4 in. (6 mm) below the finished surface. All repaired members shall be restored as close as practicable to their original dimensions.

For air temperature limits when applying shotcrete in cold weather, the first paragraph of Article 1020.14(b) shall apply. For hot weather, shotcrete shall not be applied when the air temperature is greater than 90°F (32°C). The applied shotcrete shall have a minimum temperature of 50°F (10°C) and a maximum temperature of 90°F (32°C). The shotcrete shall not be applied during periods of rain unless protective covers or enclosures are installed. The shotcrete shall not be applied when frost is present on the surface of the repair area, or the surface temperature of the repair area is less than 40°F (4°C). If necessary, lighting shall be provided to provide a clear view of the shooting area.

The shotcrete shall be applied according to ACI 506R, and shall be done in a manner that does not result in cold joints, laminations, sandy areas, voids, sags, or separations.

In addition, the shotcrete shall be applied in a manner that results in maximum densification of the shotcrete. Shotcrete which is identified as being unacceptable while still plastic shall be removed and re-applied.

Section (102BR-1)BRR

The nozzle shall normally be at a distance of 2 to 5 ft. (0.6 to 1.5 m) from the receiving surface, and shall be oriented at right angles to the receiving surface. Exceptions to this requirement will be permitted to fill corners, encase large diameter reinforcing bars, or as approved by the Engineer. For any exception, the nozzle shall never be oriented more than 45 degrees from the surface. Care shall be taken to keep the front face of the reinforcement bar clean during shooting operations. Shotcrete shall be built up from behind the reinforcement bar. Accumulations of rebound and overspray shall be continuously removed prior to application of new shotcrete. Rebound material shall not be incorporated in the work.

Whenever possible, shotcrete shall be applied to the full thickness in a single layer.

When two or more layers are required, the minimum number shall be used and shall be done in a manner without sagging or separation. A flash coat (i.e. a thin layer of up to 1/4

in. (6 mm) applied shotcrete) may be used as the final lift for overhead applications.

Prior to application of a succeeding layer of shotcrete, the initial layer of shotcrete shall be prepared according to the surface preparation and reinforcement bar cleaning requirements. Upon completion of the surface preparation and reinforcement bar treatment, water shall be applied according to the surface preparation requirements unless the surface is moist. The second layer of shotcrete shall then be applied within 30 minutes.

Shotcrete shall be cut back to line and grade using trowels, cutting rods, screeds or other suitable devices. The shotcrete shall be allowed to stiffen sufficiently before cutting. Cutting shall not cause cracks or delaminations in the shotcrete. For depressions, cut material may be used for small areas. Rebound material shall not be incorporated in the work. For the final finish, a wood float shall be used to approximately match the existing concrete texture. A manufacturer approved finishing aid may be used. Water shall not be used as a finishing aid. All repaired members shall be restored as close as practicable to their original dimensions.

Contractor operations for curing shall be continuous with shotcrete placement and finishing operations. Curing shall be accomplished using wetted cotton mats, membrane curing, or a combination of both. Cotton mats shall be applied according to Article 1020.13(a)(5) except the exposed layer of shotcrete shall be covered within 10 minutes after finishing, and wet curing shall begin immediately. Curing compound shall be applied according to Article 1020.13(a)(4), except the curing compound shall be applied as soon as the shotcrete has hardened sufficiently to prevent marring the surface, and each of the two separate applications shall be applied in opposite directions to ensure coverage. The curing compound shall be according to Article 1022.01. Note 5 of the Index Table in Article 1020.13 shall apply to the membrane curing method.

When a shotcrete layer is to be covered by a succeeding shotcrete layer within 36 hours, the repair area shall be protected with intermittent hand fogging, or wet curing with either burlap or cotton mats shall begin within 10 minutes. Intermittent hand fogging may be used only for the first hour. Thereafter, wet curing with burlap or cotton mats shall be used until the succeeding shotcrete layer is applied. Intermittent hand fogging may be extended to the first hour and a half if the succeeding shotcrete layer is applied by the end of this time.

Section (102BR-1)BRR

The curing period shall be for 7 days, except when there is a succeeding layer of shotcrete. In this instance, the initial shotcrete layer shall be cured until the surface preparation and reinforcement bar treatment is started.

If temperatures below 45°F (7°C) are forecast during the curing period, protection methods shall be used. Protection Method I according to Article 1020.13(d)(1), or Protection Method II according to Article 1020.13(d)(2) shall be used during the curing Period.

Method of Measurement This work will be measured for payment in place and the area computed in square feet.

Basis of Payment The work will be paid for at the contract unit price per square foot for PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR which payment shall constitute full compensation for furnishing all labor, equipment, tools and incidentals necessary to complete the work as specified.

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.

(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.

Section (102BR-1)BRR

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 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).

Section (102BR-1)BRR

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 (102BR-1)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 (102BR-1)BRR

Section (102BR-1)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 (102BR-1)BRR

PREFORMED BRIDGE JOINT SEAL

Effective: December 21, 2016 Revised: June 28, 2024

Description. This work shall consist of furnishing all labor, equipment and materials necessary to prepare the joint opening and install preformed bridge joint seal(s) at the locations specified.

Unless otherwise detailed on the plans or specified herein, the maximum rated movement for this joint type is 4 inches (100 mm).

Materials: Unless otherwise specified, one of the following prefabricated joint seals will be permitted.

(a) Preformed Pre-compressed, Silicone Coated, Self-Expanding Sealant System. This Sealant system shall be comprised of three components: 1) cellular polyurethane foam impregnated with hydrophobic 100% acrylic, water-based emulsion, factory coated with highway-grade, fuel resistant silicone; 2) field-applied epoxy adhesive primer, 3) field-injected silicone sealant bands.

The preformed, pre-compressed silicone joint seal shall, as a minimum, be according to the following:

• The joint seal shall be held in place by a non-sag, high modulus silicone adhesive.

• The joint seal shall be compatible with the epoxy and header material.

• The joint seal shall withstand the effects of vertical and lateral movements, skew movements and rotational movement without adhesive or cohesive failure.

• The joint seal shall be designed so that, the material is capable of movement of +50%, -50% (100% total) of nominal material size. The gland shall not contain any open, unsealed joints along its length it its final condition.

• Changes in plane and direction shall be executed using factory fabricated transition assemblies fabricated to the angle(s) specified on the plans. The transitions shall be watertight at the inside and outside corners through the full movement of the product.

• The depth of the joint shall be recessed 3/4 in. (19 mm) below the riding surface throughout the normal limits of joint movement.

• The joint seal shall be resistant to ultraviolet rays.

• The joint seal shall be resistant to abrasion, oxidation, oils, gasoline, salt, and other materials that may be spilled on or applied to the surface.

• The manufacturer shall certify that the joint composition shall be free of any waxes or wax compounds; asphalts or asphalt compounds.

Section (102BR-1)BRR

The joint material shall meet the following physical properties:

Property Requirement Test Method

Tensile Strength of Silicone Coating (min)

140 psi ASTM D 412

UV Resistance of Joint System No Changes--2000 Hours ASTM G155-00A

Density of Cellular Polyurethane Foam (Unconfined)

4.0 lb/ cu ft (200kg/cu m)

ASTM D545

Heat Aging Effects (Silicone Coating)

No cracking, chalking ASTM C 792

Joint System Operating temp range (min)

-40o F to 185o F ASTM C 711

The adhesive shall be a two-component, 100% solid, modified epoxy meeting the requirements of ASTM C881, Type I, Grade 3, Class B & C. The adhesive shall also have the following properties:

Property Requirement Test method

Tensile Strength 2,500 psi (24 MPa) min. ASTM D638

Compressive Strength 7000 psi (48 MPa) min. ASTM D695

Bond Strength (Dry Cure) 2000 psi (28MPa) min ASTM C882

Water Absorption 0.1% by weight ASTM D570

The silicone band adhesive shall have the following properties:

Movement Capability +50/-50% ASTM C 719

Elongation at Break >600% ASTM D 5893

Slump ≤=0.3" ASTM D 2202

Hardness (Shore A) max. 20 ASTM C 661 Tack free time (max) 60 minutes ASTM C 679 Heat Aging Effects No cracking, chalking ASTM C 792

Resilience ≥ 75% ASTM D5329

Bond 0% Adhesive or Cohesive Failure after 5 cycles @100%extension ASTM D 5329

Section (102BR-1)BRR

(b) Preformed Silicone Joint Seal. The preformed silicone joint seal used for this item shall conform to the following specifications:

Table 1 Physical Properties of Preformed Silicone Gland

Rated Movement Capability +2 ¼ inch total N/A

Tensile Strength, psi. 1000 min ASTM D 412

Elongation 400% min ASTM D 412

Tear (die B) 100 ppi. min ASTM D 624 Hardness Durometer (Shore A). 55 +/- 5 max ASTM D 2240

Compression set at 212°F, 70 hrs 30% max ASTM D 395

Heat Aged Properties 5pt max loss on Durometer

ASTM D 573

Tensile and Elongation % Loss 10 % max

The color of the preformed silicone seal shall be black, made by the addition of Carbon Black fillers which increases UV resistance, tensile strength, and abrasion wear properties.

The locking adhesive shall be non-sag, high modulus silicone adhesive conforming to the following specifications:

Table 2

Physical Properties of the Silicone Locking Adhesive

Tensile Strength, psi. 200 min ASTM D 412

Elongation, % 450 min ASTM D 412

Tack Free Time, minutes. 20 max. ASTM C 679 Cure Time ¼” bead, hrs 24 max ASTM C 679

Resistance to U.V. No cracking, chalking,or degradation

ASTM C793

VOC (g/L) 55 ASTM D 3960

Any rips, tears, or bond failure will be cause for rejection.

The two-part epoxy primer shall be supplied for application to the vertical faces of the joint opening. The supplied primer shall be equally as effective when bonded to concrete or steel.

This primer shall meet the following criteria:

Section (102BR-1)BRR

Table 3

Physical Properties of Preformed Silicone Joint System Primer

Viscosity (cps) 44 ASTM D 2196 Color Light Amber Visual Solids (%) 41 ASTM D 4209 Specific Gravity 0.92 ASTM D 1217 Product Flash Point (◦F, T.C.C.) 48 ASTM D 56

Package Stability N/A One year in tightly sealed containers

Cleaning N/A Mineral Spirits VOC (g/L) 520 ASTM D 3960

(c) Preformed Inverted EPDM Joint Seal. The preformed inverted EPDM joint seal used for this item shall conform to the following specifications:

Table 1 Physical Properties of Preformed Silicone Gland

Rated Movement Capability Up To 5 inch total N/A

Tensile Strength, psi. 1200 psi min ASTM D 412

Elongation 400 % min ASTM D 412 Tear (Die C) 150 pli. min ASTM D 624 Durometer Content 50 +/- 5 max ASTM D 2240

Water Resistance (70 hrs @ 100c) 10% max ASTM D 471

Ozone Resistance 100 min ASTM D 1171

Color Black Visual

Section (102BR-1)BRR

Table 2

Physical Properties of the V-Epoxy-R

V-Epoxy-R adhesive meets the requirements of ASTM C881 Type III, Grade 2. The adhesive shall also have the following properties:

Color Gray Visual

Viscosity 45,000 CP (typ.) N/A

Gel Time (minutes) 30 min. ASTM C 881 Shelf Life (Separate Sealed Containers)

12 Months N/A

Resistance to U.V. No cracking, chalking,or degradation

ASTM C793

VOC (g/L) 55 ASTM D 3960

Any rips, tears, or bond failure will be cause for rejection.

(d) Bonded Preformed Joint Seal. This joint system shall consist of preformed elastomeric seal bonded to the side walls of the joint opening using an adhesive as specified by the Manufacturer of the joint seal.

The bonded preformed joint seal shall be according to Table 1 of ASTM D2628 with the following…