IDOT 78C10-185.pdf

June 12, 2026 Letting

Notice to Bidders, Specifications and Proposal

Contract No. 78C10 WHITE County Section 101BRR-1 Route FAP 328 District 9 Construction Funds

Prepared by S 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 prevailing time 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:

WHITE County Section 101BRR-1 Route FAP 328 District 9 Construction Funds

Repairs to SN 097-0062 carrying US 45 over Skillet Fork Creek, 0.8 miles south of Mill Shoals.

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 readvertise the proposed improvement, and to waive technicalities.

By Order of the Illinois Department of Transportation

Gia Biagi, Secretary

FAP ROUTE 328 (US 45)

SECTION 101BRR-1

WHITE COUNTY

CONTRACT NO. 78C10

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

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

3 X EEO

4 X Specific EEO Responsibilities Nonfederal-Aid Contracts 5 X 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 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 i

TABLE OF CONTENTS

LOCATION OF PROJECT

DESCRIPTION OF PROJECT

TRAFFIC CONTROL PLAN

UTILITIES

PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR

CLEANING AND PAINTING BEARINGS

CLEANING AND PAINTING EXISTING STEEL STRUCTURES

BAR SPLICERS, HEADED REINFORCEMENT

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

COMPENSABLE DELAY COSTS (BDE)

DECK SLAB REPAIR

ILLINOIS WORKS APPRENTICESHIP INITIATIVE – STATE FUNDED CONTRACTS (BDE)

PAVEMENT MARKING (BDE)

REMOVAL AND DISPOSAL OF REGULATED SUBSTANCES (BDE)

SHORT TERM AND TEMPORARY PAVEMENT MARKINGS (BDE)

SIGN PANELS AND APPURTENANCES (BDE)

STEEL COST ADJUSTMENT (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 – STATE 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)

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 328 (US 45), Section 101BRR-1, White County, Contract No. 78C10, and in case of conflict with any part or parts of said Specifications, the said Special Provisions shall take precedence and shall govern.

FAP Route 328 (US 45) Section 101BRR-1

White County

LOCATION OF PROJECT

This project is located on SN 097-0062 carrying US 45 over Skillet Fork Creek. 0.8 miles south of Mill Shoals.

DESCRIPTION OF PROJECT

The proposed improvements consist of joint replacement with strip seals, bridge deck and substructure repair, and bearing cleaning and painting.

TRAFFIC CONTROL PLAN

Effective 1985 Revised 4/17/23

The road shall be kept open to traffic as follows:

(a) US 45 shall be kept open to at least one lane of traffic at all times and to two lanes of traffic to the greatest extent possible.

(b) Access to all public roads and private entrances shall be maintained during all stages of the work.

The temporary rumble strips shown on Standard 701321 will be required on this project.

UTILITIES

Effective 1984 Revised 2/15/23

Add the following after the first paragraph of Article 105.07:

Underground utilities have been plotted from available surveys and records, and, therefore, their locations must be considered approximate only. There also may be utilities for which the locations are unknown. Verification of locations of underground utilities, shown or not shown, will be the responsibility of the Contractor. The following utility companies have facilities within the project limits which may require adjustment:

Name and Address of Utility

Type

Location Estimated

Adjustment Status

CountryMark LLP 1200 Refinery Road Mt. Vernon, IN 47620 ATTN: Angie DeKemper Tel: (812) 838-8153 Cell: (812) 307-6100 Email: angie.dekemper@countrymark.com

PETROLEUM

PIPELINE

THROUGHOUT

BEFORE OR

DURING

CONSTRUCTION

Frontier Communications 208 West Union St.

Marion, IL 62959 ATTN: Rick Shaw Tel: (618) 997-0253 Cell: (618) 967-5540 Email: rick.shaw@ftr.com

COMMUNICATON

CONSTRUCTION

Hamilton County Tel. Coop Highway 142 P.O. Box 40 Dahlgren, IL. 62828 ATTN: Kevin Pyle Tel: (618) 736-2211 Cell: (618) 922-0221 Email: kevinp@hamiltoncom.net

COMMUNICATON

CONSTRUCTION

Mill Shoals, City of P.O. Box 706 Mill Shoals, IL. 62862 ATTN: Tim Isaacs Tel: (618) 516-1286

LOCAL

SANITARY

SEWER &

WATER

CONSTRUCTION

Additional utility information may be obtained by calling the "Joint Utility Location Information for Excavators" phone number, 800-892-0123. This project is located in the Mill Shoals township.

NOTIFICATION PRIOR TO STARTING WORK

Effective 12/05 Revised 2/10/17

Revise the first sentence of Article 107.09 Public Convenience and Safety to the following “The Contractor shall notify the Engineer at least 14 days in advance of starting any construction work.

For projects involving width or height restrictions or complete closures of the roadway or ramp, an additional seven days of notice (21 days total) will be required.”

This additional notification is required, so the public can be notified of the pending construction.

CHANGEABLE MESSAGE SIGNS

Revised 4/15/20

This work consists of furnishing, placing, and maintaining changeable message signs according to Section 701 and the following:

A total of two changeable message signs shall be required in this contract. All signs must be in place and operational for a minimum of 14 calendar days prior to lane or roadway closures. Each sign shall state the day work will begin and delays are possible. The exact message will be approved by the Engineer. The Contractor may be required to relocate each sign multiple times during the contract at his or her expense. The exact location of the placement of these signs shall be determined in the field by the Engineer.

The furnishing, placing, and maintaining of portable changeable message signs shall be paid for per CALENDAR DAY as CHANGEABLE MESSAGE SIGN.

COOPERATION BETWEEN CONTRACTORS

Revised 2/10/17

The Contractor is to be aware that traffic control limits of this contract may overlap those of other projects that may be under construction along I-24 concurrently with this work. The Contractor shall coordinate his/her work with the other contractors to minimize any possible conflicts. The Contractor shall also notify the Engineer five working days in advance of any work that may affect other adjacent contracts. Adjacent contracts are

Adjacent Project, Contract No. 78B13: US 45 resurfacing, IL 14 to White/Wayne County line.

Work under Contract 78C10 shall not commence until all work of the adjacent project within traffic control limits of this contract has been completed.

PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR

Effective: March 14, 2018

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.

Materials. Materials shall be according to the following:

Item Article/Section

(a) Portland Cement Concrete (Note 1)

(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 ½”.

Note 2. The concrete shall be from the “Approved List of Non-Shrink Grouts” maintained by the Bureau of Materials and Physical Research. The repair material chosen shall be appropriate for the thickness of repair to be made. Coarse aggregate with a maximum size of ⅜” shall be added with the amount as specified by the manufacturer.

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 C1116.

The packaged shotcrete shall have a water-soluble chloride ion content of less than 0.40 lb/cu yd. The test shall be performed according to ASTM C1218, and the hardened shotcrete shall have an age of 28 to 42 days at the time of the 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% or a maximum ASTM C 1293 expansion of 0.040%. However, the ASTM C 1260 value may be increased to 0.27% for each individual aggregate if the cement total equivalent alkali content (Na2O + 0.658K2O) does not exceed 0.60%. As an alternative to these requirements, ASTM C 1567 testing which shows the packaged shotcrete has a maximum expansion of 0.16% may be submitted. The ASTM C 1260, C 1293, or C1567 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 at 14 days.

The packaged shotcrete shall be limited to the following proportions:

The Portland cement and finely divided minerals shall be 6.05 cwt/cu yd to 8.50 cwt/cu yd for type FA and 6.05 cwt/cu yd to 7.50 cwt/cu yd for type CA. The Portland cement shall not be below 4.70 cwt/cu yd for type FA or CA.

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

Class F fly ash is optional, and the maximum shall be 20% by weight of cement.

Class C fly ash is optional, and the maximum shall be 25% by weight of cement.

Ground granulated blast-furnace slag is optional and the maximum shall be 30% by weight of cement.

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

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%.

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.

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. 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, removed the existing concrete to sound concrete along the edges of the damaged areas to a depth of 1” min. to 1½” max. The edges shall be saw cut ¾” 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 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 void filled and compacted.

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

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 say cut ¾” 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 repairs 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.

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

Basis of Payment. This 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.

FRP STRENGTHENING FOR PPC I-BEAM REPAIRS

Effective: March 14, 2018 Revised: February 19, 2021

Description. This work shall consist of furnishing and installing fiber-reinforced polymer (FRP) wraps at the locations shown in the plans. The FRP strengthening shall be of the size, type, layer, materials, tension, and spacing shown in the plans. The Contractor shall submit drawings of the FRP strengthening system, showing materials, components, and installation procedures to the Engineer for approval prior to ordering materials and commencing work.

All other concrete repairs and/or modifications shall be completed prior to performing this work.

Concrete placed in areas receiving FRP wraps shall have a maximum moisture content of 4% using a digital moisture meter before wrapping begins unless bond testing shows no detrimental effect for installing prior to obtaining the required moisture content. All manufacturer’s recommendations for surface preparation and installation of FRP wraps shall be followed.

Submittals. The following submittals, but not limited to, shall be required of the FRP system manufacturer, installation contractor and inspection agency. All submittals, except daily installation data logs, shall be given to the Engineer for review allowing at least 60 days for approval.

Submittals required of the FRP system manufacturer:

• Product information and data sheets indicating physical, mechanical and chemical properties and limitations of the FRP system and all its components.

• Tensile properties for the FRP system shall be reported in accordance with ASTM D7565 in units of kips/inch/ply for strength and modulus (stiffness). FRP systems not reporting their design properties in accordance with ASTM D7565 are not allowed.

• Durability test data and structural test reports of the FRP system for the proposed application in the expected environmental conditions.

• Installation and maintenance instructions and general recommendations regarding each material used in the FRP system. Note that surface preparation requirements shall be included in the installation procedures.

• Material Safety Data Sheets of each product used and certification that all materials abide by all local, state, and federal environmental and worker’s safety laws and regulations.

• Quality control procedures for tracking FRP materials and material certifications.

• List of projects where similar FRP system has been implemented.

Submittals required of the FRP system installation Contractor:

• Documentation from the FRP system manufacturer stating the Contractor has been trained to install the FRP system show on the design plans.

• List of completed projects by the Contractor where similar FRP system has been implemented. Include location, owner, engineer and contact numbers associated with each project.

• Quality control procedures, daily installation data logs, and any other inspection forms used by the Contractor. If an independent inspection agency is used, the following submittals are required of the FRP system inspection agency:

• Qualifications and a list of each inspector used on the project.

• Sample inspection forms to be used during inspection.

• List of prior inspections performed by each inspector used on the project.

Material Requirements. The Contractor shall inspect and ensure all materials meet specifications, conform to design plans and are undamaged upon job-site arrival. All products shall be delivered to the job-site in their original, un-opened containers with the Manufacturer’s name, labels, product identification, and batch numbers. Ensure FRP system materials are protected from chemicals, dirt, extreme, temperatures, moisture, and physical damage, by storing, handling, and applying materials according to manufacturer and OSHA recommendations.

FRP shall be high modulus, high strength fiber fabric of the type, size, layer, materials, tension, spacing and location as specified on the design plans. FRP Reinforcement shall meet the requirements as listed below.

Minimum FRP Cured Composite Property Requirements Property Carbon Fiber ASTM Test

Method Prior to testing, laminate samples shall be cured at least 7 days at 70°F then post-cured at 140°F for 48 hours

Tensile Strength 140 ksi D3039 Tensile Modulus 11000 ksi D3039 Elongation at break 1.0% D3039 Thickness per Layer* 0.035 in.

Unit Tensile Strength 5.6 k/in/layer D7565 Unit Tensile Modulus 440 k/in/layer D7565

* Individual layer thickness may not exceed 0.05 in.

Fabric saturant (saturating resin) and concrete primer shall be two-component, 100% solids, tolerant to moisture, high strength and high modulus epoxy. Manufacturer’s recommendations for mixing shall be followed. Components of saturating resin may be proportioned; however, provision shall be made for checking the accuracy of proportions and mixing. Dilution of components will not be permitted. Mixtures shall be used within its pot life.

A vapor permeable, UV resistant polymer or acrylic based protective coating shall be used. The protective coating shall be applied according to the manufacturer’s recommendations.

Construction Requirements. A technical representative from the manufacturer shall be on site at the start of the installation and for as long as needed to ensure the Contractor is installing the material in accordance with the Installation manual. All costs associated with providing a technical representative shall be the responsibility of the Contractor.

The Contractor shall maintain a Daily Installation Log. The log shall be available for review by the Engineer, and a copy shall be furnished to the Engineer at completion of installation and construction for each day’s production. The Log shall provide material traceability and process records for each wrap and shall include all the following information:

(a) Date, time and specific location of installation.

(b) Construction and installation requirements, including plans and drawings and references thereto.

(c) Surface preparation methods.

(d) Widths and lengths of cracks not injected with epoxy.

(e) Material information including product description, data of manufacturer, product and fiber batch numbers, mixture ratios, mixing times, appearance description of mixed resins (i.e.

primers, putties, saturants, adhesives, and protective coatings used for the day)

(f) Ambient temperatures, humidity, and general weather observations at the beginning, middle and end of each wrap installation shift.

(g) Concrete surface temperature, concrete moisture content and surface cleanliness.

(h) Heat sources used for increase surface temperature or curing.

(i) Number of FRP layers used, composite thickness measurements, curing progress of resins including full documentation of curing temperature ramping and final curing temperature and thickness measurements of protecting coating used.

(j) Location and size of FRP debonding or air voids.

(k) Documentation stating installation procedures were followed.

(l) Pull off test results including bond strength, failure mode, and location.

(m) Other general work progress.

Surface Preparation: FRP wraps shall be placed on sound concrete having a maximum moisture content of 4% using a digital moisture meter unless bond testing shows no detrimental effect for installing prior to obtaining the required moisture content. All bond inhibiting and foreign materials, including but not limited to dust, laitance, paint, grease, curing compounds, impregnations and waxes, shall be removed from the concrete surface by blast cleaning or equivalent mechanical means. All concrete surfaces shall be air blasted and vacuumed clean to a dust-free condition.

All concrete surface irregularities shall be ground smooth and/or filled with an approved repair technique. See special provision for Precast Prestressed Concrete I-Beam Repair for concrete repair at bottom flanges of beams and for the concrete repair of exposed vertical reinforcement at side faces of beam. All sharp edges shall be ground smooth and flush. All repairs shall be completed in such a manner as to not damage the existing structure.

When wrapping FRP around exterior corners of rectangular cross sections, the corners should be rounded to a minimum of ½” radius. Interior corners shall be smoothed by troweling epoxy mortar into the corners. After concrete surface preparation has been completed, adhesive strength of the concrete shall be verified by random pull-off testing according to ACI 503R as per the direction of the Engineer.

All cracks greater than 0.007 in. shall be injected with epoxy according to Section 590 of the Standard Specifications for Road and Bridge Construction and paid for as Epoxy Crack Injection.

Constituent Material Application: All materials shall be applied according to conditions (i.e. surface temperature of the concrete, air temperature, relative humidity, and corresponding dew point) recommended by the FRP manufacturer.

Components of saturating resin may be proportioned and mixed by hand or by automatic equipment. Provision shall be made for checking the accuracy of proportions and mixing. Diluting is not permitted.

The saturating resin shall be applied to a properly prepared substrate as a surface primer. The primer should be applied uniformly on the prepared surface to all areas of concrete receiving the FRP wrap according to the manufacturer’s specifications. Primed surfaces shall be protected from all contaminants (e.g. dust, moisture, etc.) prior to the application of the FRP wraps.

The resin-to-fabric ratio shall be verified and documented on the daily installation data log.

Saturating resin shall be applied uniformly to prepared surfaces. FRP-ply orientation shall not deviate from the orientation shown on the design plans. Fiber wraps shall be handled in a manner to maintain fiber straightness and prevent fiber damage. Any kinks, folds, or severe waviness should be reported to the Engineer. If multiple fabric layers are being placed, successive layers shall be placed before the complete curing of the previous layer to ensure complete bonding between layers. Entrapped air beneath each layer of fabric shall be rolled out before the saturating resin sets.

Subject to approval by the Engineer, the Contractor may provide suitable enclosures to permit application and curing of the fiber wrap during inclement weather. Provisions shall be made to control atmospheric conditions artificially within the enclosures within the limits specified for application and curing of the fiber wrap.

The FRP system shall be protected from rain, sand, dust, and other foreign particles during and after curing as per the Engineer and manufacturer’s recommendations.

The Contractor shall inspect the cured FRP system to ensure saturating resin has completely cured. The Contractor must check for defects such as voids, delaminations, external cracks, chips, cuts, loose fibers, external abrasions, blemishes, foreign inclusions, depressible raised areas, or fabric wrinkles. All defects with a dimension greater than 1½ inch, or an area greater than one square inch, or defects with any dimension greater than 1 inch within one foot from another defect area of similar size, shall be repaired or replaced as determined by the Engineer.

Repairs shall be made according to manufacturer’s recommendations and as specified by the Engineer. For large defected areas, additional layers of FRP maybe required as per the Engineer.

A vapor permeable, UV resistant polymer or acrylic based protective coating shall be used. The protective coating shall be compatible with the FRP system and applied according to the manufacturer’s recommendations. Any solvents used to clean the FRP surface prior to the application of the protective coating shall be approved by the FRP manufacturer since solvents can have harmful effects on the polymer fabric. Two layers of protective coating shall be applied to all surfaces of the fiber wrap. The cost of the protective coating shall be paid for as Acrylic Coating.

Method of Measurement. FRP wraps will be computed for payment in place in square feet based on the surface area measurements of the FRP in each orientational direction. The measured quantity will not be modified for multiple layers of FRP needed as shown in the design plans.

The areas upon which the protective coat is applied will be measured for payment in place and the area computed in square yards.

Basis of Payment. This work will be paid for at the contract unit price per SQUARE FOOT for FIBER WRAP. Payment shall constitute full compensation for all materials, labor, tools, equipment, and incidentals necessary to complete the work.

Full compensation for any additional testing, materials, enclosures, or work required because of the use of a particular type of fiber wrap, shall be considered as included in the item fiber wrap.

Protective coat will be paid for at the contract unit price per SQUARE YARD for ACRYLIC

COATING.

CLEANING AND PAINTING BEARINGS

Description. This work shall consist of the satisfactory cleaning and painting of the steel materials on the existing bridge bearings as indicated on the plans and to the satisfaction of the Engineer.

This work also includes cleaning and painting all appurtenances associated with the bearings, including retainer angles or plates and anchors at the bridge seats, if present.

This work also includes the satisfactory collection and disposal of paint cleaning residues and all debris generated by the cleaning process in accordance with the specifications. Manual tools with vacuum systems shall be utilized to complete the work.

Materials. Paint materials shall be according to the Cleaning and Painting Existing Steel Structures special provision.

Construction Requirements. The existing bridge bearings shall be cleaned and painted in accordance with the Cleaning and Painting Existing Steel Structures special provision.

Method of Measurement. This work will be measured for payment per each completed and accepted.

Basis of Payment. This work will be paid for at the contract unit price per EACH for CLEANING AND PAINTING BEARINGS, which price shall include all material, equipment, and labor to satisfactorily complete the work.

CLEANING AND PAINTING EXISTING STEEL STRUCTURES

Effective: October 2, 2001 Revised: October 17, 2025

Description. This work shall consist of the preparation of all designated metal surfaces by the method(s) specified on the plans. This work also includes the painting of those designated surfaces. This work also includes caulking locations designated on the plans and painting with the paint system(s) specified on the plans. The Contractor shall furnish all materials, equipment, labor, and other essentials necessary to accomplish this work and all other work described herein and as directed by the Engineer.

Materials. All materials to be used on an individual structure shall be produced by the same manufacturer.

The Bureau of Materials and Physical Research has established a list of all products that have met preliminary requirements. Each batch of material, except for the penetrating sealer, shall be tested and assigned a CMMS approval number before use. The specified colors shall be produced in the coating manufacturer’s facility. Tinting of the coating after it leaves the manufacturer’s facility is not allowed.

The paint materials shall meet the following requirements of the Standard Specification and as noted below:

Item Article

(a) Waterborne Acrylic 1008.04

(b) Aluminum Epoxy Mastic 1008.03

(c) Organic Zinc Rich Primer 1008.05

(d) Epoxy/ Aliphatic Urethane 1008.05

(e) Penetrating Sealer (Note 1)

(f) Moisture Cured Zinc Rich Urethane Primer (Note 2)

(g) Moisture Cured Aromatic/Aliphatic Urethane (Note 2)

(h) Moisture Cured Penetrating Sealer (Note 3)

(i) Caulk (Polyurethane Joint Sealant) 1050.04

Note 1: The Epoxy Penetrating Sealer shall be a cross-linked multi component sealer. The sealer shall have the following properties:

(a) The volume solids shall be 98 percent (plus or minus 2 percent).

(b) Shall be clear or slightly tinted color.

Note 2: These material requirements shall be according to the Special Provision for the Moisture

Cured Urethane Paint System.

Note 3: The Moisture Cured Penetrating Sealer manufacturer’s certification will be required.

Submittals. The Contractor shall submit for Engineer review and acceptance, the following plans and information for completing the work. The submittals shall be provided within 30 days of execution of the contract unless given written permission by the Engineer to submit them at a later date. Work cannot proceed until the submittals are accepted by the Engineer. Details for each of the plans are presented within the body of this specification.

a) Contractor/Personnel Qualifications. Evidence of Contractor qualifications and the names and qualifications/experience/training of the personnel managing and implementing the Quality Control program and conducting the quality control tests, and certifications for the CAS (Coating Application Specialists) on SSPC-QP1 and QP2 projects.

b) Quality Control (QC) Program. The QC Program shall identify the following: the instrumentation that will be used, a schedule of required measurements and observations, procedures for correcting unacceptable work, and procedures for improving surface preparation and painting quality as a result of quality control findings. The program shall incorporate at a minimum, the IDOT Quality Control Daily Report form, or a Contractor form (paper or electronic) that provides equivalent information.

c) Inspection Access Plan. The inspection access plan for use by Contractor QC personnel for ongoing inspections and by the Engineer during Quality Assurance (QA) observations.

d) Surface Preparation/Painting Plan. The surface preparation/painting plan shall include the methods of surface preparation and type of equipment to be utilized for washing, hand/power tool cleaning, removal of rust, mill scale, paint or foreign matter, abrasive blast or water jetting, and remediation of chloride. If detergents, additives, or inhibitors are incorporated into the water, the Contractor shall include the names of the materials and Safety Data Sheets (SDS). The Contractor shall identify the solvents proposed for solvent cleaning together with SDS.

If cleaning and painting over existing galvanized surfaces are specified, the plan shall address surface preparation, painting, and touch up/repair of the galvanized surfaces.

The plan shall also include the methods of coating application and equipment to be utilized.

If the Contractor proposes to heat or dehumidify the containment, the methods and equipment proposed for use shall be included in the Plan for the Engineer’s consideration.

e) Paint Manufacturer Certifications and Letters. When a sealer is used, the Contractor shall provide the manufacturer’s certification of compliance with IDOT testing requirements listed under “Materials” above. A certification regarding the compatibility of the sealer with the specified paint system shall also be included.

When rust inhibitors are used, the Contractor shall provide a letter from the coating manufacturer indicating that the inhibitor is compatible with and will not adversely affect the performance of the coating system.

If the use of a chemical soluble salt remover is proposed by the Contractor, provide a letter from the coating manufacturer indicating that the material will not adversely affect the performance of the coating system.

The paint manufacturer's most recent application and thinning instructions, SDS and product data sheets shall be provided, with specific attention drawn to storage temperatures, and the temperatures of the material, surface and ambient air at the time of application.

A letter or written instructions from the coating manufacturer shall be provided indicating the length of time that each coat must be protected from cold or inclement weather (e.g., exposure to rain) during its drying period, the maximum recoat time for each coat, and the steps necessary to prepare each coat for overcoating if the maximum recoat time is exceeded.

f) Abrasives. Abrasives to be used for abrasive blast cleaning, including SDS. For expendable abrasives, the Contractor shall provide certification from the abrasive supplier that the abrasive meets the requirements of SSPC-AB1. For steel grit abrasives, the certification shall indicate that the abrasive meets the requirements of SSPC-AB3.

g) Protective Coverings. Plan for containing or controlling paint debris (droplets, spills, overspray, etc.). Any tarpaulins or protective coverings proposed for use shall be fire retardant. For submittal requirements involving the containment used to remove lead paint, the Contractor shall refer to Special Provision for Containment and Disposal of Lead Paint Cleaning Residues.

h) Progress Schedule. Progress schedule shall be submitted per Article 108.02 and shall identify all major work items (e.g., installation of rigging/containment, surface preparation, and coating application).

When the Engineer accepts the submittals, the Contractor will receive written notification. The Contractor shall not begin any paint removal work until the Engineer has accepted the submittals.

The Contractor shall not construe Engineer acceptance of the submittals to imply approval of any particular method or sequence for conducting the work, or for addressing health and safety concerns. Acceptance of the programs does not relieve the Contractor from the responsibility to conduct the work according to the requirements of Federal, State, or Local regulations and this specification, or to adequately protect the health and safety of all workers involved in the project and any members of the public who may be affected by the project. The Contractor remains solely responsible for the adequacy and completeness of the programs and work practices, and adherence to them.

Contractor Qualifications. Unless indicated otherwise on the contract plans, for non lead abatement projects, the painting Contractor shall possess current SSPC–QP1 certification.

Unless indicated otherwise on the plans, for lead abatement projects the Contractor shall also possess current SSPC-QP2 certification. The Contractor shall maintain certified status throughout the duration of the painting work under the contract. The Department reserves the right to accept Contractors documented to be currently enrolled in the SSPC-QP7, Painting Contractor Introductory Program, Category 2, in lieu of the QP certifications noted above.

Quality Control (QC) Inspections. The Contractor shall perform first line, in process QC inspections. The Contractor shall implement the submitted and accepted QC Program to ensure that the work accomplished complies with these specifications. The designated Quality Control inspector shall be onsite full time during any operations that affect the quality of the coating system (e.g., surface preparation and chloride remediation, coating mixing and application, and evaluations between coats and upon project completion). The Contractor shall use the IDOT Quality Control Daily Report form to record the results of quality control tests. Alternative forms (paper or electronic) will be allowed provided they furnish equivalent documentation as the IDOT form, and they are accepted as part of the QC Program submittal. The completed reports shall be turned into the Engineer before work resumes the following day. The Engineer or designated representative will sign the report. The signature is an acknowledgment that the report has been received but should not be construed as an agreement that any of the information documented therein is accurate.

Contractor QC inspections shall include, but not be limited to the following:

• Suitability of protective coverings and the means employed to control project debris and paint spills, overspray, etc.

• Ambient conditions

• Surface preparation (solvent cleaning, pressure washing including chalk tests, hand/power tool or abrasive blast cleaning, etc.)

• Chloride remediation

• Coating application (specified materials, mixing, thinning, and wet/dry film thickness)

• Recoat times and cleanliness between coats

• Coating continuity and coverage (freedom from runs, sags, overspray, dryspray, pinholes, shadow-through, skips, misses, etc.)

The personnel managing the Contractor’s QC Program shall possess a minimum classification of Society of Protective Coatings (SSPC) BCI certified, National Association of Corrosion Engineers (NACE) Coating Inspector Level 2 - Certified and shall provide evidence of successful inspection of 3 bridge projects of similar or greater complexity and scope that have been completed in the last 2 years. Copies of the certification and experience shall be provided. References for experience shall be provided and shall include the name, address, and telephone number of a contact person employed by the bridge owner.

The personnel performing the QC tests shall be trained in coatings inspection and the use of the testing instruments. Documentation of training shall be provided. The QC personnel shall not perform hands on surface preparation or painting activities. Painters shall perform wet film thickness measurements, with QC personnel conducting random spot checks of the wet film. The Contractor shall not replace the QC personnel assigned to the project without advance notice to the Engineer, and acceptance of the replacement(s), by the Engineer.

The Contractor shall supply all necessary equipment with current calibration certifications to perform the QC inspections. Equipment shall include the following at a minimum:

• Sling psychrometer or digital psychrometer for the measurement of dew point and relative humidity, together with all necessary weather bureau tables or psychrometric charts. In the event of a conflict between readings with the sling psychrometer and the digital psychrometer, the readings with the sling psychrometer shall prevail.

• Surface temperature thermometer

• SSPC Visual Standards VIS 1, Guide and Reference Photographs for Steel Surfaces

Prepared by Dry Abrasive Blast Cleaning; SSPC-VIS 3, Visual Standard for Power and Hand-Tool Cleaned Steel; SSPC-VIS 4, Guide and Reference Photographs for Steel Prepared by Water Jetting, and/or SSPC-VIS 5, Guide and Reference Photographs for Steel Prepared by Wet Abrasive Blast Cleaning, as applicable.

• Test equipment for determining abrasive cleanliness (oil content and water-soluble contaminants) according to SSPC abrasive specifications AB1, AB2, and AB3.

• Commercially available putty knife of a minimum thickness of 40 mils (1mm) and a width between 1 and 3 in. (25 and 75 mm). Note that the putty knife is only required for projects in which the existing coating is being feathered and tested with a dull putty knife.

• Testex Press-O-Film Replica Tape and Micrometer compliant with Method C of ASTM D4417, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel, or digital profile depth micrometer compliant with ASTM D4417, Method B. In the event of a conflict between measurements with the two instruments on abrasive blast cleaned steel, the results with the Testex Tape shall prevail. Note that for measuring the profile of steel power tool cleaned to SSPC-SP15, Commercial Grade Power Tool Cleaning, the digital profile depth micrometer shall be used.

• Bresle Cell Kits or CHLOR*TEST kits for chloride determinations, or equivalent

• Wet Film Thickness Gage

• Blotter paper for compressed air cleanliness checks

• Type 2 Electronic Dry Film Thickness Gage per SSPC - PA2, Procedure for Determining

Conformance to Dry Coating Thickness Requirements

• Standards for verifying the accuracy of the dry film thickness gage

• Light meter for measuring light intensity during paint removal, painting, and inspection activities

• All applicable ASTM and SSPC Standards used for the work (reference list attached)

The accuracy of the instruments shall be verified by the Contractor's personnel according to the equipment manufacturer's recommendations and the Contractor’s QC Program. All inspection equipment shall be made available to the Engineer for QA observations on an as needed basis.

Hold Point Notification. Specific inspection items throughout this specification are designated as Hold Points. Unless other arrangements are made at the project site, the Contractor shall provide the Engineer with a minimum 4-hour notification before a Hold Point inspection will be reached.

If the 4-hour notification is provided and the Work is ready for inspection at that time, the Engineer will conduct the necessary observations. If the Work is not ready at the appointed time, unless other arrangements are made, an additional 4-hour notification is required. Permission to proceed beyond a Hold Point without a QA inspection will be granted solely at the discretion of the Engineer, and only on a case by case basis.

Quality Assurance (QA) Observations. The Engineer will conduct QA observations of any or all phases of the work. The presence or activity of Engineer observations in no way relieves the Contractor of the responsibility to provide all necessary daily QC inspections of his/her own and to comply with all requirements of this Specification.

The Engineer has the right to reject any work that was performed without adequate provision for QA observations.

Inspection Access and Lighting. The Contractor shall facilitate the Engineer’s observations as required, including allowing ample time to…