ildot 64T48-022.pdf

Letting July 31, 2026

Notice to Bidders, Specifications and Proposal

Contract No. 64T48 WHITESIDE County Section (105BR-1)BRR Route FAS 1197 Project STP-0YS9(101) 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.

July 31, 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. 64T48 WHITESIDE County Section (105BR-1)BRR Project STP-0YS9(101) Route FAS 1197 District 2 Construction Funds

Bridge repairs and joint replacement on SN 098-0102, carrying Moline Rd over drainage ditch, 1 mile northeast of Lyndon.

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

FAS Route 1197 (Moline Road)

Section (150BR-1)BRR

Whiteside County

INDEX

FOR

SUPPLEMENTAL SPECIFICATIONS

AND RECURRING SPECIAL PROVISIONS

Adopted January 1, 2026

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

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

SUPPLEMENTAL SPECIFICATIONS

Std. Spec. Sec. Page No.

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

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

Section (150BR-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 Concrete Mix Design – Department Provided 32 Station Numbers in Pavements or Overlays

Section (150BR-1)BRR i

TABLE OF CONTENTS

LOCATION OF PROJECT

DESCRIPTION OF PROJECT

TRAFFIC CONTROL PLAN

PCC AUTOMATIC BATCHING EQUIPMENT

PCC QC/QA ELECTRONIC REPORTS SUBMITTAL

AVAILABILITY OF ELECTRONIC FILES

APPROACH SLAB REPAIR

BAR SPLICERS, HEADED REINFORCEMENT

BRIDGE DECK GROOVING (LONGITUDINAL)

CLEANING AND PAINTING BEARINGS

FIBER WRAP

PRECAST PRESTRESSED CONCRETE I-BEAM REPAIR

CLEANING AND PAINTING EXISTING STEEL STRUCTURES

DIAMOND GRINDING AND SURFACE TESTING BRIDGE SECTIONS

BRIDGE DECK GROOVING (LONGITUDINAL)

BAR SPLICERS, HEADED REINFORCEMENT

BRIDGE DECK CONCRETE OVERLAYS

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

COMPENSABLE DELAY COSTS (BDE)

CONCRETE BARRIER (BDE)

DECK SLAB REPAIR

DISADVANTAGED BUSINESS ENTERPRISE PARTICIPATION (BDE)

GUARDRAIL (BDE)

HOT-MIX ASPHALT (BDE)

PAVEMENT MARKING (BDE)

PERFORMANCE GRADED ASPHALT BINDER (BDE)

REMOVAL AND DISPOSAL OF REGULATED SUBSTANCES (BDE)

RESIDENTIAL DRIVEWAY TEMPORARY SIGNAL (BDE)

SHORT TERM AND TEMPORARY PAVEMENT MARKINGS (BDE)

SIGN PANELS AND APPURTENANCES (BDE)

SOURCE OF SUPPLY AND QUALITY REQUIREMENTS (BDE)

Section (150BR-1)BRR ii

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)

WEEKLY DBE TRUCKING REPORTS (BDE)

WORK ZONE TRAFFIC CONTROL DEVICES (BDE)

WORK ZONE WIDTH RESTRICTION (BDE)

WORKING DAYS (BDE)

Section (150BR-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 FAS Route 1197 (Moline Road), Project STP-0YS9(101), Section (150BR- 1)BRR, Whiteside County, Contract No. 64T48 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 project is located on Moline Road over drainage ditch in Lyndon Township.

DESCRIPTION OF PROJECT

The work consists of bridge deck scarification and overlay, bridge deck patching repairs, bridge substructure repair, bridge joint repair, hot-mix asphalt removal and resurfacing, guardrail removal and replacement, pavement markings, and all incidental and collateral work necessary to complete the improvements as shown in the plans and as described herein. The gross and net length of the project is approximately 0.15 miles.

Section (150BR-1)BRR

TRAFFIC CONTROL PLAN

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

Standards:

701001 701006 701011 701201 701301 701311 701321 701901

Details:

Work Zone 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.

Pavement Marking:

Temporary pavement markings shall be tape. Highway Standards Application:

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 of the lane closure allowing the deck and pavement repairs, latex concrete overlay, beam guard repair and replacement, 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.

Section (150BR-1)BRR

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 involved 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.

Other Devices:

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.

Traffic Control for Narrow Travel Lanes: The Contractor shall provide informational warning signs regarding narrow travel lanes in construction areas. MAX WIDTH XX’-XX” X MILES AHEAD (W12- I103-48) signs with a width restriction of 13’-6” shall be installed as noted on the plans.

The material of these signs shall be 0.125 inch thick aluminum, Type AP White and fluorescent orange reflective sheeting, and 6 inch D Series font Black vinyl lettering meeting the requirements of Sections 1090 and 1091 of the Standard Specification.

Maintenance of Traffic:

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

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.

The Contractor shall notify Whiteside County, 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.

Section (150BR-1)BRR

PCC AUTOMATIC BATCHING EQUIPMENT

Effective: January 1, 2015 Revised: January 31, 2023

Portland cement concrete provided shall be produced from batch plants that conform to the requirements of Article 1103.03 (a) and (b) of the Standard Specifications for Road and Bridge Construction. Semi-automatic batching will not be allowed.

Plants shall have computerized batching interfaced with a printer. IDOT Producer Number, IDOT Design Number, Concrete Material Code, batch weights, aggregate mixtures, water added, amount of each admixture or additive, and percent variance from design shall be printed for each batch. Tickets shall state the actual water-cement ratio as batched, and the amount of water that can be added to the batch without exceeding the maximum water-cement ratio. Truck delivery tickets are still required as per Article 1020.11(a)(7) of the Standard Specifications.

PCC QC/QA ELECTRONIC REPORTS SUBMITTAL

Effective: January 1, 2015 Revised: January 31, 2023

The Contractor’s QC personnel shall be responsible for electronically submitting the following reports to the Department: PRO and IND data for BMPR MI654 “Concrete Air, Slump, and Quantity,”; PRO data for BMPR MI655 “P.C. Concrete Strength,” and PRO data for BMPR MI504 “Aggregate Gradation” reports to the Department. The format for the electronic submittals shall be the QMP package reporting program, which will be provided by the Department. Microsoft Excel 2007 or newer and Microsoft Outlook is required for this program which shall be provided by the Contractor.

AVAILABILITY OF ELECTRONIC FILES

Effective: 10/16 Revised: 1/29/25

Electronic files of this project will be made available to the Contractor after the contract has been awarded. This information will be provided upon request in a Bentley CONNECT Platform software format ONLY. If data is required in other formats, it will be your responsibility to make these conversions. The Contractor shall coordinate obtaining electronic files through the Project Engineer. If there is a conflict between the electronic files and the printed contract plans and documents, the printed contract plans and documents shall take precedence over the electronic files. The Contractor shall accept all risk associated with using the electronic files and shall hold the Department harmless for any errors or omissions in the electronic files and the data contained therein. Errors or delays resulting from the use of the electronic files by the Contractor shall not result in an extension of time for any interim or final completion date or shall not be considered cause for additional compensation. The Contractor shall not use, share, or distribute these electronic files except for the purpose of constructing this contract. Any claims by third parties due to use or errors shall be the sole responsibility of the Contractor.

The Contractor shall include this disclaimer with the transfer of these electronic files to any other parties and shall include appropriate language binding them to similar responsibilities.

Section (150BR-1)BRR

APPROACH SLAB REPAIR

Effective: March 13, 1997

Description. This work shall consist of bituminous surface removal, when required, the removal and disposal of all loose and deteriorated concrete and the replacement with new concrete to the original top of approach slab. The work shall be done according to the applicable requirements of Sections 501, 503, and 1020 of the Standard Specifications and this Special Provision.

Approach slab repairs will be classified as follows:

(a) Partial-Depth. Partial-depth repairs shall consist of removing the loose and unsound approach slab concrete, disposing of the concrete removed and replacing with new concrete. The removal may be performed by chipping with power-driven hand tools or by hydro equipment. The depth shall be measured from the original concrete surface, at least 20 mm (3/4 inch) but not more than 140 mm (5 ½ inches) unless otherwise specified in the plans.

(b) Full-Depth. Full-depth repairs shall consist of removing concrete full-depth of the slab, disposing of the concrete removed, and replacing with new concrete to the original approach slab surface. The removal may be performed with power-driven hand tools or by hydro equipment.

Materials. All materials shall comply with the requirements of Sections 503 and 1020 of the Standard Specifications.

Concrete for partial and full-depth repairs shall be proportioned and mixed according to the applicable portions of Section 1020 of the Standard Specifications except as follows:

No calcium chloride will be permitted in the mix.

BAR SPLICERS, HEADED REINFORCEMENT

Effective: September 2, 2022 Revised: October 27, 2023

Add the following to Article 508.08(b):

When bar splicers are epoxy-coated, all damaged or uncoated areas near the threaded ends shall be coated with a two-part epoxy according to ASTM D 3963 (D 3963M). All threaded ends of Stage II construction threaded splicer bars shall be coated according to ASTM D 3963 or dipped in an epoxy-mastic primer prior to joining the Stage II construction threaded splicer bar to the threaded coupler.

Add the following Article 508.02 (d)

Bar Terminators ............................................................................................................................... 1006.10(a)(1) h

Section (150BR-1)BRR

Add the following paragraph after Article 508.08 (c):

Bar terminators are threaded, headed attachments to reinforcement to form headed reinforcement. When specified on the plans, a bar terminator shall be attached to the designated reinforcement for development.

Add the following 4th paragraph to Article 508.11:

Bar Terminators will be paid for at the contract unit price per each for BAR TERMINATORS.

Add the following to Article 1006.10(a)(1)g:

For bar splicers with welded connections between the threaded coupler and threaded rod, the Stage I construction threaded splicer bar shall be welded to the threaded coupler using an all- around fillet weld.

Add the following Article 1006.10(a)(1)h:

Bar Terminators. Designated bars shall use a bar terminator to form headed reinforcement.

Headed reinforcement shall conform to ASTM A970 with threaded attachment; Class HA; and reinforcement bars conforming to ASTM A706, except the connection strength of the bar terminator to the reinforcement bar shall meet, in tension, at least 125 percent of the specified yield strength of the reinforcement bar. The bar terminator shall be on the Department’s qualified product list.

When the reinforcement bar to receive the bar terminator is epoxy coated, the bar terminator shall also be epoxy coated according to ASTM A 775 (A 775M)

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

Section (150BR-1)BRR

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).

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.

The 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. Containment of paint cleaning residues per IDOT GBSP 26 or 60 will not be required, but manual tools with vacuum systems shall be utilized to complete the work.

Materials. Paint materials shall be according to the following special provision:

1. GBSP 25, "Cleaning and Painting Existing Steel Structures"

Construction Requirements. The existing bridge bearings shall be cleaned and painted in accordance with the following special provision:

1. GBSP 25, "Cleaning and Painting Existing Steel Structures"

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

Section (150BR-1)BRR

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.

FIBER WRAP

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.

Section (150BR-1)BRR

• 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 insure 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.

Section (150BR-1)BRR

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.

Section (150BR-1)BRR

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.

Section (150BR-1)BRR

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.

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.

Materials. Materials shall be according to the following:

Item Article/Sectio n

(a) Portland Cement Concrete (Note 1)

(b) Non-shrink Grout (Note 2) ............................................................................................................................. 1024.0

(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 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

Section (150BR-1)BRR 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.

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.

Section (150BR-1)BRR

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.

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 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

Section (150BR-1)BRR 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.

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 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 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.

Section (150BR-1)BRR

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.

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 ¾ 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.

Section (150BR-1)BRR

For air temperature limits when applying shotcrete in cold weather, the first…