ILDOT 76R96-078.pdf

Letting September 18, 2026

Notice to Bidders, Specifications and Proposal

Contract No. 76R96 RANDOLPH County Section 125-1BR-1 Route FAP 329 Project BR-UML2(687) District 8 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.

September 18, 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. 76R96 RANDOLPH County Section 125-1BR-1 Project BR-UML2(687) Route FAP 329 District 8 Construction Funds

Bridge painting, joint repair/replacement and deck overlay on SN 079-0013 carrying IL 154 over the Kaskaskia River.

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

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

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

By Order of the Illinois Department of Transportation

Gia Biagi, Secretary

FAP ROUTE 329 (IL 154)

PROJECT BR-UML2(687)

SECTION 125-1BR-1

RANDOLPH COUNTY

CONTRACT NO. 76R96

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 125-1BR-1

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 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 125-1BR-1

i

TABLE OF CONTENTS

LOCATION OF PROJECT

DESCRIPTION OF PROJECT

SUBMITTAL OF EEO/LABOR DOCUMENTATION

TRAFFIC CONTROL PLAN

INSTALLATION OF TEMPORARY CONCRETE BARRIERS AND/OR TEMPORARY BRIDGE RAIL

STATUS OF UTILITIES TO BE ADJUSTED

WIDTH RESTRICTION SIGNING

COAST GUARD COORDINATION AND RESTRICTIONS

MODULAR EXPANSION JOINT

CLEANING AND PAINTING CONTACT SURFACE AREAS OF EXISTING STEEL STRUCTURES

CLEANING AND PAINTING EXISTING STEEL STRUCTURES

CONTAINMENT AND DISPOSAL OF LEAD PAINT CLEANING RESIDUES

DIAMOND GRINDING AND SURFACE TESTING BRIDGE SECTIONS

BRIDGE DECK CONSTRUCTION

BRIDGE DECK GROOVING (LONGITUDINAL)

HOT DIP GALVANIZING FOR STRUCTURAL STEEL

BAR SPLICERS, HEADED REINFORCEMENT

BRIDGE DECK CONCRETE OVERLAYS

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

COMPENSABLE DELAY COSTS (BDE)

CONSTRUCTION AIR QUALITY – DIESEL RETROFIT (BDE)

DECK SLAB REPAIR

DISADVANTAGED BUSINESS ENTERPRISE PARTICIPATION (BDE)

GUARDRAIL (BDE)

HOT-MIX ASPHALT (BDE)

PAVEMENT MARKING (BDE)

PERFORMANCE GRADED ASPHALT BINDER (BDE)

RAISED REFLECTIVE PAVEMENT MARKERS (BDE)

REMOVAL AND DISPOSAL OF REGULATED SUBSTANCES (BDE)

SHORT TERM AND TEMPORARY PAVEMENT MARKINGS (BDE)

SIGN PANELS AND APPURTENANCES (BDE)

SOURCE OF SUPPLY AND QUALITY REQUIREMENTS (BDE)

STEEL COST ADJUSTMENT (BDE)

SUBCONTRACTOR AND DBE PAYMENT REPORTING (BDE)

SUBCONTRACTOR MOBILIZATION PAYMENTS (BDE)

SECTION 125-1BR-1

ii

SUBMISSION OF BIDDERS LIST INFORMATION (BDE)

SUBMISSION OF PAYROLL RECORDS – FEDERAL AID CONTRACT (BDE)

SURVEYING SERVICES (BDE)

TEMPORARY CONCRETE BARRIER (BDE)

TEMPORARY RUMBLE STRIPS (BDE)

TRAINING SPECIAL PROVISIONS (BDE)

IDOT TRAINING PROGRAM GRADUATE ON-THE-JOB TRAINING SPECIAL PROVISION

WEEKLY DBE TRUCKING REPORTS (BDE)

WORK ZONE TRAFFIC CONTROL DEVICES (BDE)

WORK ZONE WIDTH RESTRICTION (BDE)

WORKING DAYS (BDE)

PROJECT LABOR AGREEMENT

SECTION 125-1BR-1

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 329 (IL 154), Project BR-UML2(687), Section 125-1BR-1, Randolph County, Contract No. 76R96, 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 329 (IL 154) Project BR-UML2(687)

Section 125-1BR-1 Randolph County

Contract No. 76R96

LOCATION OF PROJECT

The project is located on IL 154 over the Kaskaskia River in Randolph County on SN 079-0013.

DESCRIPTION OF PROJECT

The project consists of replacement of microsilica concrete overlay, joint replacement at the abutments and pier 4 with preformed joint strip seals, joint replacement at pier 1 with a modular expansion joint, replacement of floor drains with full-depth deck slab repairs around new drains, replacement of end diaphragms with galvanized end diaphragms, and cleaning and painting of beam ends and fascia beams.

SUBMITTAL OF EEO/LABOR DOCUMENTATION

Effective: April 2016

This work shall be done in accordance with Check Sheets No. 1, 3, and 5 of the IDOT Supplemental Specifications and Recurring Special Provisions and the Weekly DBE Trucking Reports (BDE) special provision, except as here-in modified.

PAYROLL AND STATEMENT OF COMPLIANCE:

Certified payroll (FORM SBE 48 OR AN APPROVED FACSIMILE) and the Statement of Compliance (FORM SBE 348) shall be submitted by two methods:

SECTION 125-1BR-1

1. By Mail (United States Postal Service): The ORIGINAL of the certified payroll and the Statement of Compliance for the Prime Contractor and each Subcontractor shall be submitted by mail to the Regional Engineer for District 8.

2. Electronically: Scan both the ORIGINAL of the certified payroll and the Statement of

Compliance to the same PDF file, and email to the District at the email address designated by the District EEO Officer.

SBE 48 and SBE 348 forms shall be submitted weekly and will be considered late if received after midnight seven business days after the payroll ending date.

WEEKLY DBE TRUCKING REPORT:

The Weekly DBE Trucking Report (FORM SBE 723) shall be submitted electronically.

Scan the form to a PDF file, and email to the District at the email address designated by the District EEO Officer.

SBE 723 forms shall be submitted weekly and will be considered late if received after midnight ten business days following the reporting period.

MONTHLY LABOR SUMMARY & MONTHLY CONTRACT ACTIVITY REPORTS:

The Monthly Labor Summary Report (MLSR) shall be submitted by one of two methods:

1. For contractors having IDOT contracts valued in the aggregate at $250,000 or less, the report may be typed or clearly handwritten using Form D8 PI0148. Submit the ORIGINAL report by mail to the Regional Engineer for District Eight. Contractors also have the option of using the method #2 outlined below.

2. For contractors having IDOT contracts valued in the aggregate at more than

$250,000, the report must be submitted in a specific “Fixed Length Comma Delimited ASCII Text File Format”. This file shall be submitted by e-mail using specific file formatting criteria provided by the District EEO Officer. Contractors must submit a sample text file to District 8 for review at least 14 days prior to the start of construction.

The Monthly Contract Activity Report (MCAR) may be typed or clearly handwritten using Form D8 PI0149.

The MLSR and the MCAR shall be submitted concurrently. If the method of transmittal is method #1 above, then both the MLSR and the MCAR shall be mailed together in the same envelope. If the method of transmittal is method #2 above, then the MCAR shall be scanned to a .pdf file and attached to the email containing the MLSR .txt file.

The MLSR and MCAR must be submitted for each consecutive month, for the duration of the project, and will be considered late if received after midnight ten calendar days following the reporting period.

REQUEST FOR APPROVAL OF SUBCONTRACTOR:

SECTION 125-1BR-1

The ORIGINAL and one copy of the Request for Approval of Subcontractor (FORM BC 260A) shall be submitted to the District at the IDOT Preconstruction Conference.

SUBSTANCE ABUSE PREVENTION PROGRAM CERTIFICATION:

The ORIGINAL and one copy of the Substance Abuse Prevention Program Certification (FORM BC 261) shall be submitted to the District at the IDOT Preconstruction Conference.

The Contractor is required to follow submittal procedures as provided by the EEO Officer at the preconstruction conference and to follow all revisions to those procedures as issued thereafter.

If a report is rejected, it is the Contractor’s responsibility to make required adjustments and/or corrections and resubmit the report. Reports not submitted and accepted within the established timeframes will be considered late.

Disclosure of this information is necessary to accomplish the statutory purpose as outlined under 23CFR part 230 and 41CFR part 60.4 and the Illinois Human Rights Act. Disclosure of this information is REQUIRED. Failure to comply with this special provision may result in the withholding of payments to the Contractor and/or cancellation, termination, or suspension of the contract in whole or part.

This special provision must be included in each subcontract agreement.

ALL HARD COPY FORMS TO BE SUBMITTED TO:

Region 5 Engineer Illinois Department of Transportation

ATTN: EEO/LABOR OFFICE

1102 Eastport Plaza Drive Collinsville, IL 62234-6198

Compliance with this special provision shall be included in the cost of the contract, and no additional compensation will be allowed for any costs incurred.

TRAFFIC CONTROL PLAN

Effective: July 12, 1993 Revised: May 12, 1997

Traffic control shall be in accordance with the applicable sections of the “Standard Specifications for Road and Bridge Construction”, the applicable guidelines contained in the “National Manual on Uniform Traffic Control Devices for Streets and Highways”, Illinois Supplement to the National Manual of Uniform Traffic Control Devices, these special provisions, and any special details and highway standards contained herein and in the plans.

Special attention is called to Articles 107.09 and 107.14 of the “Standard Specifications for Road and Bridge Construction” and the following highway standards relating to traffic control:

701201 701306 701311 701321 701326 701901

In addition, the following special provision(s) will also govern traffic control for this project:

SECTION 125-1BR-1

Installation of Temporary Concrete Barriers and/or Temporary Bridge Rail Work Zone Traffic Control Devices Width Restriction Signing Temporary Concrete Barrier Temporary Rumble Strips Work Zone Width Restriction

INSTALLATION OF TEMPORARY CONCRETE BARRIERS AND/OR TEMPORARY BRIDGE

RAIL

Effective: May 18, 1993 Revised: November 1, 2006

The following procedure and traffic control shall be used for the placement, relocation, and removal of temporary concrete barrier and/or temporary bridge rail on this project:

Placement of Temporary Concrete Barrier and/or Temporary Bridge Rail:

1. Erect Standard 701321 as shown on the plans for stage 1 construction except for the temporary concrete barrier and/or temporary bridge rail.

2. Place the temporary traffic signals in the red flash mode.

3. Close the stage 1 construction lane to traffic, and route two-way traffic over the stage 1 traffic lane. One flagman will be required at each end of the lane closure at all times to direct traffic.

4. Erect the temporary concrete barrier and/or temporary bridge rail in the stage 1 location beginning at the approach end of the lane closure and proceeding to the departure end.

Relocation of Temporary Concrete Barrier and/or Temporary Bridge Rail:

1. When stage 1 construction is complete, relocate temporary concrete barrier tapers parallel to the roadway centerline beginning at the departure end and proceeding to the approach end. Place cones at 25 ft centers to establish temporary tapers to close the stage 2 construction lane to traffic and route traffic over the stage 2 traffic lane.

2. Place the temporary concrete barrier and/or temporary bridge rail in the stage 2 location starting with the approach end and proceed to the departure end.

3. This procedure shall be followed for any adjustment of temporary concrete barrier and/or bridge rail during any stage.

Removal of the Temporary Concrete Barrier and/or Temporary Bridge Rail:

1. When stage 2 construction is completed, remove the temporary concrete barrier and/or temporary bridge rail beginning at the departure end of the lane closure and proceeding to the approach end. Place cones at 25 ft centers to delineate the closed lane until all the temporary concrete barrier and/or bridge rail is removed.

2. Remove Standard 701321, and route two-way traffic over the structure.

Additional Requirements During Placement, Relocation, and Removal of Temporary Concrete Barrier and/or Temporary Bridge Rail:

1. One lane of traffic shall be maintained at all times.

SECTION 125-1BR-1

2. Workers and equipment will not be permitted to encroach on the lane open to traffic.

3. Any length of temporary concrete barrier and/or temporary bridge rail not completed in a one-day time period shall be protected by barricades with steady-burning lights at 25 ft centers until the barrier work is complete. A temporary attenuator shall be placed on the end of any length of temporary concrete barrier and/or temporary bridge rail not completed.

4. Traffic control devices, as specified on the plans for Standard 701321, shall be placed on all temporary concrete barrier and/or temporary bridge rail in use overnight.

The cost of complying with this procedure shall be considered included in the cost of Temporary Concrete Barrier, Relocating Temporary Concrete Barrier, and/or Temporary Bridge Rail outlined in the plans.

STATUS OF UTILITIES TO BE ADJUSTED

NO UTILITIES TO BE ADJUSTED

The above represents the best information of the Department and is only included for the convenience of the bidder. The applicable provisions of Sections 102 and 103 and Articles 105.07, and 107.20 of the Standard Specifications for Road and Bridge Construction shall apply.

If any utility adjustment or removal has not been completed when required by the Contractor's operations, the Contractor should notify the Engineer in writing. A request for an extension of time will be considered to the extent the Contractor's operations were affected.

WIDTH RESTRICTION SIGNING

This work shall consist of the width restriction signage as shown on the plans and as described herein.

All signs required will be supplied to the Contractor by the Department. The Contractor shall give the Department’s Bureau of Operations two weeks of notice for the signs. Contact Jean Slape at 618-394-2189. The Contractor shall pick up the signs at the T.M. Building in Fairview Heights and return them upon completion of the contract.

The Contractor shall furnish the posts and erect the signs at the locations shown on the plans, as direct by the Engineer. The posts shall remain the property of the Contractor. The height to the bottom of the lowest sign shall not be less than 6 feet.

This work will be paid for at the contract unit price per LUMP SUM for WIDTH RESTRICTION

SIGNING.

SECTION 125-1BR-1

COAST GUARD COORDINATION AND RESTRICTIONS

The paint containment system is to hang no lower than 3’ below the profile of the low beam and shall not restrict the width between the piers. The paint containment system shall be able to be removed or to be moved up to within 1’ of the profile of the low beam in the event the Coast Guard directs due to high water conditions.

Prior to commencing work, the Contractor shall submit a written work plan to the US Coast Guard for review and approval. The work plan shall include the nature of the work, restrictions to the normal horizontal and vertical clearances, descriptions of temporary works such as rescue boats, barges, and work platforms, time of year, days of operation, hours of operation, and a point of contact available 24 hours per day, seven days a week through the project duration.

The Engineer shall coordinate communication between the Contractor and the US Coast Guard.

Submit to:

Eric Washburn Bridge Supervisor, Western Rivers U.S. Coast Guard District 8 Bridge Branch 1222 Spruce Street St. Louis, MO 63103 314-269-2378 Eric.Washburn@uscg.mil

SECTION 125-1BR-1

MODULAR EXPANSION JOINT

Effective: May 19, 1994 Revised: October 27, 2023

Description. This work shall consist of furnishing and installing a modular expansion joint(s) as shown on the plans, and according to applicable portions of Section 520 of the Standard Specifications.

General. The expansion joint device shall be capable of handling the specified longitudinal movement. In addition, when specified, the joint shall also be capable of handling the differential non-parallel longitudinal movement. The expansion joint device shall effectively seal the joint opening in the deck surface and barrier curbs against the entrance of water and foreign materials.

There shall be no appreciable change in the deck surface plane with the expansion and contraction movements of the bridge.

The device shall consist of a shop-fabricated modular assembly of transverse elastomeric seals, edge and center beams, bearing on support bars spanning the joint opening. The assembly shall maintain equal distances between intermediate support rails, at any cross section, for the entire length of the joint. The assembly shall be stable under all conditions of expansion and contraction.

The noise level of the joint in service shall meet all Federal and State of Illinois noise requirements.

At sidewalks, concrete median barriers and concrete parapet joints, a sliding steel plate shall be fabricated and installed according to the plans. Painting or galvanizing of sliding steel plates shall be as specified on the plans.

Suppliers: The Department maintains a pre-qualified list of proprietary structural systems allowed for modular expansion joints. This list can be found on the Departments web site under Prequalified Structural Systems. The Contractor’s options are limited to those systems pre-qualified by the Department on the date that the contract was bid. These systems have been reviewed for structural feasibility and adequacy only. Presence on this list shall in no case relieve the Contractor of the site-specific design or QC/QA requirements stated herein.

The supplier shall notify the Department at least two weeks in advance of fabrication of the fabrication shop address. The fabricator shall provide evidence of current certification by AISC according to Article 106.08(e) of the Standard Specifications.

Submittals: Shop drawings and a copy of the calculations and support documents shall be submitted to the Engineer for approval according to Article 105.04 of the Standard Specifications.

Calculations shall be sealed by an Illinois Licensed Professional Engineer. Submittals will be required for each modular expansion joint device specified. In addition, the Contractor shall provide the Department with a certification of compliance by the manufacturer listing all materials in the system. The certification shall attest that the system conforms to the design requirements, material requirements, and that all components of the joint are the same as what was included in the prequalification submittal that was successfully tested in the OMV, seal push out, and fatigue tests of Section 19, Appendix 19, Article 5.1, 5.2, and 5.3 of the AASHTO LRFD Bridge Construction Specifications. Submittals with insufficient test data and supporting certifications will be rejected.

The shop drawings shall include tables showing the total anticipated movements for each joint and the required setting width of the joint assemblies at various temperatures.

SECTION 125-1BR-1

The shop drawings shall include installation drawings or details showing locations and details of temporary installation supports, and joint assembly components, in relation to the adjacent primary structural beams, girders, or members. These details shall demonstrate that the proposed modular expansion joint is designed to fit and operate around all primary structural members within the space provided on the contract plans.

Fabrication: Fabricators of the modular expansion device(s) are required to meet the following tolerances:

Allowable variation in straightness of center beam rails

Length < 30’ Length 30’ to 45’ Length > 45’

1/8” per 10’ total length 3/8” 3/8” + 1/8”*(total length (feet) – 45’)/10’

Allowable lateral variation in specified location of support boxes ±1/4”

Allowable lateral variation in specified location of stirrup or other attachments to center beam ±1/16”

Allowable variation in total depth ±1/8” Allowable vertical dimension variation of all components ±1/8” Allowable variation from specified elevation end squareness or skew ±1/8”

Allowable variation in overall length of joint ±1”

Metallic attachments used to secure elastomeric seals to centerbeams, if welded to the centerbeams and edge beams, shall be welded continuously along either their top or bottom edges.

Run off tabs shall be used for stirrup or other attachments to the center beam full penetration welds.

Design Requirements: The maximum vertical, transverse and horizontal rotations and displacements shall be defined and included in the design.

The expansion joint device(s) shall be designed, detailed and successfully tested, according to Section 14 of the AASHTO LRFD Bridge Design Specifications.

The design forces used for centerbeam to support bar analysis shall be taken at the centerline of the centerbeam.

The maximum fatigue resistance of any detail shall not exceed that associated with the fatigue category prescribed in the table below.

SECTION 125-1BR-1

Type of Detail Maximum Permitted

Category Welded Multiple Centerbeam to Support Bar Connections C Weld Stirrup Attachments for Single Support Bar Systems C

Bolted Stirrup Attachments for Single Support Bar Systems D Groove Welded Centerbeam Splices B Miscellaneous Welded Connections1 C Miscellaneous Bolted Connections D

1Miscellaneous connections include attachments for equidistant devices and any metallic attachments to the centerbeams or edge beams that are used to secure the elastomeric seals.

In addition, expansion joint device(s) shall be designed for the vehicular live load as specified on the General, Plan, and Elevation sheet of the plans across the entire width of the structure.

Top, bottom and sides of support bars shall be restrained to prevent uplift, transmit bearing loads, and maintain the lateral position of the bars.

The total service movement of each individual sealing element shall not exceed 3 in. (75 mm).

The joint supplier shall design, layout, and detail the modular expansion joint assembly and components to miss existing or proposed structural beams, girders, or members. Cutting of structural members to install joint assemblies shall not be permitted.

Materials:

(a) Metals. Structural Steel. All structural steel, except stainless steel, shall be according to

AASHTO M 270, Grade 50 or 50W (M 270M Grade 345), unless otherwise specified. All structural steel, except stainless steel, shall be hot-dip galvanized according to ASTM A123 or A153 as applicable.

Stainless steel sheets for the sliding surfaces of the support bars shall conform to the requirements of ASTM A240 (A240M) type 302 or 304. Stainless steel mating surfaces shall require a No. 8 finish. For non-mating surfaces a 2B finish is required.

The use of aluminum components in the modular joint will not be allowed.

(b) Preformed Elastomeric Seals. The elastomeric sealing element shall be according to ASTM

D5973.

Lubricant/Adhesive for installing the preformed elastomeric elements in place shall be a one-part, moisture-curing, polyurethane and hydrocarbon solvent mixture as recommended by the manufacturer and containing not less than 65 percent solids.

(c) Support Bar Bearings. Support bar bearings shall be fabricated from elastomeric pads with polytetrafluorethylene (PTFE) surfacing or from polyurethane compound with PTFE sliding surfaces. The elastomeric and PTFE materials shall meet the requirements of Section 1083 of the Standard Specifications.

SECTION 125-1BR-1

(d) Support Bars. Support bars shall incorporate stainless steel sliding surfaces to permit joint movement.

Construction Requirements

General. Installation of expansion devices shall be according to the plans and shop drawings.

The fabricator of the modular joint assembly shall be AISC certified according to Article 106.08 for Bridge and Highway Metal Component Manufacturers. In lieu of AISC certification, the Contractor may have all welding on main members (support bars and center beams) observed and inspected by independent (third party) personnel at the Contractor’s expense. Welding shall then be observed by a Certified Welding Inspector (CWI) in addition to the manufacturer's own welding inspection. Third-party Non-Destructive Examination (NDE) shall be performed by inspector(s), certified as level II in applicable methods, and all complete penetration beam-to-bar welds and butt joints in beams shall be UT inspected and 10 percent of fillet and partial pen welds shall be MT inspected.

The manufacturer of the expansion device shall provide a qualified technical service representative to supervise installation. Modular expansion joint devices shall be factory prefabricated assemblies, preset by the manufacturer prior to shipment with provisions for field adjustment for the ambient temperature at the time of installation.

Unless otherwise shown on the plans, the neoprene seals shall be continuous without any field splices. Installation of the joint seals shall be performed by a trained representative of the Manufacturer.

The metal surfaces in direct contact with the neoprene seals shall be blast cleaned to permit a high strength bond of the lubricant/adhesive between the neoprene seal and mating metal surfaces.

The Contractor shall anticipate and make all necessary adjustments to existing or plan-specified reinforcement bars, subject to the approval of the Engineer, in order to prevent interferences with placement of the selected joint in the structure. Any adjustments to reinforcement bars interfering with the joint installation shall be the responsibility of the Contractor and preapproved by the Engineer prior to installation of the joint. Cutting of reinforcement shall be minimized, and any bars that are cut shall be replaced in-kind at no additional cost.

The prefabricated joint assembly shall be properly positioned and attached to the structure according to the manufacturer’s approved shop drawings. The attachment shall be sufficiently rigid to prevent non-thermal rotation, distortion, or misalignment of the joint system relative to the deck prior to casting the concrete. The joints shall be adjusted to the proper opening based on the ambient temperature at the time of installation and then all restraints preventing thermal movement shall be immediately released and/or removed. The joint upturn may be recessed 1 inch into the parapet to allow for lateral adjustment. The joint assembly units shall be straight, parallel and in proper vertical alignment or reworked until proper adjustment is obtained prior to casting of the concrete around the joint.

After the joint system is installed, the joint area shall be flooded with water and inspected, from below for leakage. If leakage is observed, the joint system shall be repaired, at the expense of the Contractor, as recommended by the manufacturer and approved by the Engineer.

SECTION 125-1BR-1

Method of Measurement. This work will be measured for payment in place, in feet (meters), along the centerline of the joint. All sliding plate assemblies at the sidewalks, parapets and median barriers will not be measured for payment. The size will be defined as the specified longitudinal movement rounded up to the nearest 3 inch (75 mm) increment.

Basis of Payment: When only a longitudinal movement is specified, this work will be paid for at the contract unit price per foot (meter) for the MODULAR EXPANSION JOINT, of the size specified. When a differential non-parallel movement is also specified, this work will be paid for at the contract unit price per foot (meter) for the MODULAR EXPANSION JOINT-SWIVEL, of the size specified.

All materials, equipment and labor required to fabricate, paint and install the sliding plate assemblies at the sidewalks, parapets and median barriers will not be paid for separately but shall be included in the price for the expansion joint specified.

When the fabrication and erection of modular expansion joint is accomplished under separate contracts, the applicable requirements of Article 505.09 shall apply, except the furnishing pay items shall include storage and protection of fabricated materials up to 75 days after the completion dates.

Fabricated modular expansion joints and other materials complying with the requirements of this item, furnished and accepted, will be paid for at the contract unit price per foot (meter) for FURNISHING MODULAR EXPANSION JOINT or FURNISHING MODULAR EXPANSION JOINT

– SWIVEL of the size specified.

Storage and care of fabricated joints and other materials complying with the requirements of this item by the Fabrication Contractor beyond the specified storage period, will be paid for at the contract unit price per calendar day for STORAGE OF MODULAR EXPANSION JOINTS if a pay item is provided for in the contract, or will be paid for according to Article 109.04 if a pay item is not provided in the contract.

Modular expansion joints and other materials erected according to the requirements of the specifications, and accepted, will be paid for at the contract unit price per foot (meter) for ERECTING MODULAR EXPANSION JOINT or ERECTING MODULAR EXPANSION JOINT - SWIVEL of the size specified.

SECTION 125-1BR-1

CLEANING AND PAINTING CONTACT SURFACE AREAS OF EXISTING STEEL

STRUCTURES

Effective: June 30, 2003 Revised: October 23, 2020

Description. This work shall consist of the surface preparation and painting of existing steel structures in areas that will be in contact with new steel.

The existing steel at primary connections (faying surfaces) shall be prepared and primed as specified herein prior to connecting new structural steel to the existing structure.

The existing steel at secondary connections shall be prepared, and if bare metal is exposed, primed as specified herein prior to connecting new structural steel to the existing structure.

General. The existing coatings shall be assumed to contain lead and may also contain other toxic metals. Any plans that may be furnished for the work, and any dimensions or other information given regarding a structure, are only for the purpose of assisting bidders in determining the type and location of steel to be cleaned and painted. It is the responsibility of the Contractor to verify this information and the accuracy of the information provided shall in no way affect the price bid for structural steel.

Materials. The Bureau of Materials and Physical Research has established a list of all products that have met preliminary requirements. Each batch of material must be tested and approved before use.

The paint materials shall meet the requirements of the following articles of the Standard Specification:

Item Article

a) Organic Zinc Rich Primer 1008.05

b) Aluminum Epoxy Mastic 1008.03

Submittals:

a) Manufacturer's application instructions and product data sheets. Copies of the paint manufacturer's application instructions and product data sheets shall be furnished to the Engineer at the field site before steel cleaning begins.

b) Waste Management Plan. The Waste Management Plan shall address all aspects of waste handling, storage, testing, hauling and disposal. Include the names, addresses, and a contact person for the proposed licensed waste haulers and disposal facilities. Submit the name and qualifications of the laboratory proposed for Toxicity Characteristic Leaching Procedure (TCLP) analysis.

c) 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.

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Construction Requirements. 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, coating mixing and application, and evaluations between coats and upon completion of the work). The Contractor shall provide artificial lighting in areas where natural light is inadequate, as determined by the Engineer, to allow proper cleaning, inspection, and painting.

Illumination for inspection shall be at least 30 foot-candles (325 LUX). Illumination for cleaning and priming, including the working platforms, access, and entryways shall be at least 20 foot-candles (215 LUX).

The Contractor shall be responsible for any damage caused to persons, vehicles, or property, except as indemnified by the Response Action Contractor Indemnification Act. Whenever the intended purposes of the protective devices are not being accomplished, as determined by the Engineer, work shall be immediately suspended until corrections are made. Painted surfaces damaged by any Contractor's operation shall be removed and repainted, as directed by the Engineer, at the Contractor's expense.

Weather Conditions. Surfaces to be primed after cleaning shall remain free of moisture and other contaminants. The Contractor shall control his/her operations to ensure that dust, dirt, or moisture does not come in contact with surfaces cleaned prior to painting. Surfaces painted shall be protected until the coating is sufficiently cured to protect itself from damage.

Restrictions on ambient conditions shall be as per the coating manufacturer’s written specifications.

Surface Preparation: Prior to making connections or painting, all loose abrasives, paint, and residue shall be contained, collected, removed from the surface area and properly disposed of as specified later in this specification.

Soluble Salt Remediation. The Contractor shall implement surface preparation procedures and processes that will remove chloride from the surfaces to levels below 7 micrograms per square centimeter. Surfaces that may be contaminated with chloride include, but are not limited to, expansion joints and all areas that are subject to roadway splash or runoff such as fascia beams and stringers. Surfaces shall be tested for chlorides at a frequency of five tests per bearing line, with tests performed on both the beams and diaphragms/cross-frames at expansion joints.

Methods of chloride removal may include, but are not limited to, hand washing, steam cleaning, or pressure washing with or without the addition of a chemical soluble salt remover as approved by the coating manufacturer and scrubbing before or after initial paint removal. The Contractor may also elect to clean the steel and allow it to rust overnight followed by recleaning, or by utilizing blends of fine and coarse abrasives during blast cleaning, wet abrasive/water jetting methods of preparation, or combinations of the above. If steam or water cleaning methods of chloride removal are utilized over surfaces where the coating has been completely removed, and the water does not contact any lead containing coatings, the water does not have to be collected. The Contractor shall provide the proposed procedures for chloride remediation in the Surface Preparation/Painting Plan.

Upon completion of the chloride remediation steps, the Contractor shall use cell methods of field chloride extraction and test procedures (e.g., silver dichromate) accepted by the Engineer, to test

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representative surfaces that were previously rusted (e.g., pitted steel) for the presence of remaining chlorides. Remaining chloride levels shall be no greater than 7µg/sq cm as read directly from the surface without any multiplier applied to the results. The testing must be performed, and the results must be acceptable, prior to painting each day.

A minimum of 5 tests per 1000 sq. ft. (93 sq m) or fraction thereof completed in a given day, shall be conducted at project start up. If results greater than 7 µg/sq cm are detected, the surfaces shall be recleaned and retested at the same frequency. If acceptable results are achieved on three consecutive days in which testing is conducted, the test frequency may be reduced to 1 test per 1000 sq. ft. (93 sq. m) prepared each day provided the chloride remediation process remains unchanged. If unacceptable results are encountered, or the methods of chloride remediation are changed, the Contractor shall resume testing at a frequency of 5 tests per 1000 sq. ft. (93 sq. m).

Following successful chloride testing the chloride test areas shall be cleaned as specified below.

Painted surfaces of new steel damaged by abrasive blasting or by the Contractor's operations shall be repainted, as directed by the Engineer, at the Contractor's expense.

a) Primary Connections. Primary connections shall be defined as faying (contact) surfaces of high-strength bolted connections specifically noted in plans.

The surfaces of existing steel in all areas that will be in direct contact with new steel shall be prepared according to SSPC-SP15, Commercial Grade Power Tool Cleaning using vacuum-shrouded power tools equipped with HEPA filtration. The surface preparation shall remove all rust, mill scale, and existing paint from the contact surface. At the Contractors option, vacuum blast cleaning according to SSPC-SP6, Commercial Blast Cleaning may be substituted for SSPC-SP15 at no additional cost to the Department. The surface profile for primary connection surfaces shall be 1.5 to 3.5 mils (38 to 90 microns).

b) Secondary Connections. Secondary connections shall be defined as all surface areas of existing members that will be in contact with new steel except as previously defined as primary connections.

These surfaces of existing steel in all areas that will be in direct contact with new steel shall be prepared according to SSPC-SP3, Power Tool Cleaning using vacuum-shrouded power tools equipped with HEPA filtration. The surface preparation shall remove all loose rust, loose mill scale, and loose, checked, alligatored and peeling paint from the contact surface. At the Contractors option, vacuum blast cleaning according to SSPC-SP6, Commercial Blast Cleaning or SSPC-SP15, Commercial Grade Power Tool Cleaning may be substituted for SSPC-SP3 at no additional cost to the Department. The surface profile for abrasive blast cleaning and Commercial Grade Power Tool Cleaning shall be 1.5 to 3.5 mils (38 to 90 microns).

Painting. The manufacturer’s written instructions shall be followed for paint storage, mixing, thinning, application, ambient conditions, and drying times between coats. The surface shall be free of dirt, dust, and debris prior to the application of any coat. The coatings shall be applied as a continuous film of uniform thickness free of defects including, but not limited to, runs, sags, overspray, dryspray, pinholes, voids, skips, misses, and shadow-through. Defects such as runs and sags shall be brushed out immediately during application.

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The Engineer will approve surface preparation prior to priming.

a) For Primary connections the surface of the prepared steel cleaned to bare metal shall be primed with an organic zinc rich primer between 3.5 and 5.0 mils (90 and 125 microns) dry film thickness.

b) For Secondary Connections the surface of the prepared steel cleaned to bare metal shall be painted with either one coat of epoxy mastic between 5 and 7 mils (125 microns to 180 microns) in thickness or one coat of an organic zinc rich primer between 3.5 and 5.0 mils (90 and 125 microns) in thickness. Areas not cleaned to bare metal need not be painted.

For primary connections, the primer on the surface of the prepared steel shall cure according to the manufacturers instructions prior to connecting new structural steel to the existing structure.

For secondary connections, the primer on the surface of the prepared steel need only be dry to touch prior to connecting new steel to the existing structure.

The surrounding coating at each prepared location shall be feathered for a minimum distance of 1 1/2 in. (40 mm) to achieve a smooth transition between the prepared areas and the existing coating.

Collection, Temporary Storage, Transportation and Disposal of Waste. The Contractor and the Department are considered to be co-generators of the waste.

The Contractor is responsible for all aspects of waste collection, testing and identification, handling, storage, transportation, and disposal according to these specifications and all applicable Federal, State, and Local regulations. The Contractor shall provide for Engineer review and acceptance a Waste Management Plan that addresses all aspects of waste handling, storage, and testing, and provides the names, addresses, and a contact person for the proposed licensed waste haulers and disposal facilities. The Department will not perform any functions relating to the waste other than provide EPA identification numbers, provide the Contractor with the emergency response information, the emergency response telephone number required to be provided on the manifest, and to sign the waste manifest. The Engineer will obtain the identification numbers from the state and federal environmental protection agencies for the bridge(s) to be painted and furnish those to the Contractor.

All surface preparation/paint residues shall be collected daily and deposited in all-weather containers supplied by the Contractor as temporary storage. The storage area shall be secure to prevent unauthorized entry or tampering with the containers. Acceptable measures include storage within a fully enclosed (e.g., fenced in) and locked area, within a temporary building, or implementing other reasonable means to reduce the possibility of vandalism or exposure of the waste to the public or the environment (e.g., securing the lids or covers of waste containers and roll-off boxes). Waste shall not be stored outside of the containers. Waste shall be collected and transferred to bulk containers taking extra precautions as necessary to prevent the suspension of residues in air or contamination of surrounding surfaces. Precautions may include the transfer of the material within a tarpaulin enclosure. Transfer into roll-off boxes shall be planned to minimize the need for workers to enter the roll-off box.

No residues shall remain on uncontained surfaces overnight. Waste materials shall not be removed through floor drains or by throwing them over the side of the bridge. Flammable materials shall not be stored around or under any bridge structures.

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The all-weather containers shall meet the requirements for the transportation of hazardous materials and as approved by the Department. Acceptable containers include covered roll-off boxes and 55-gallon drums (17H). The Contractor shall insure that no breaks and no deterioration of these containers occurs and shall maintain a written log of weekly inspections of the condition of the containers. A copy of the log shall be furnished to the Engineer upon request. The containers shall be kept closed and sealed from moisture except during the addition of waste.

Each container shall be permanently identified with the date that waste was placed into the container, contract number, hazardous waste name and ID number, and other information required by the IEPA.

The Contractor shall have each waste stream sampled for each project and tested by TCLP and according to EPA and disposal company requirements. The Engineer shall be notified in advance when the samples will be collected. The samples shall be collected and shipped for testing within the first week of the project, with the results due back to the Engineer within 10 days. The costs of testing shall be considered included in this work. Copies of the test results shall be provided to the Engineer prior to shipping the waste.

The existing paint removed, together with the surface preparation media (e.g. abrasive) shall be handled as a hazardous waste, regardless of the TCLP results. The waste shall be transported by a licensed hazardous waste transporter, treated by an IEPA permitted treatment facility to a non-hazardous special waste and disposed of at an IEPA permitted disposal facility in Illinois.

The treatment/disposal facilities shall be approved by the Engineer and shall hold an IEPA permit for waste disposal and waste stream authorization for this cleaning residue. The IEPA permit and waste stream authorization must be obtained prior to beginning cleaning, except that if necessary, limited paint removal will be permitted in order to obtain samples of the waste for the disposal facilities. The waste shall be shipped to the facility within 90 days of the first accumulation of the waste in the containers. When permitted by the Engineer, waste from multiple bridges in the same contract may be transported by the Contractor to a central waste storage location(s) approved by the Engineer in order to consolidate the material for pick up, and to minimize the storage of waste containers at multiple remote sites after demobilization. Arrangements for the final waste pickup shall be made with the waste hauler by the time blast cleaning operations are completed or as required to meet the 90-day limit stated above.

The Contractor shall submit a waste accumulation inventory table to the Engineer no later than the 5th day of the month.