J4- BRFB_Special Project Specifications.docx

BRIDGE APPROACH SLABS

DESCRIPTION

Construct reinforced concrete slabs at bridge approaches, including curbs and sidewalks; furnish and place temporary slope drains; remove existing pavement or approach slab; furnish and place concrete, reinforcing steel, joint filler, sealer and other materials; finish and cure concrete.

Construct the approach slabs after the adjacent bridge deck is cast and before constructing concrete barrier rails or sidewalks.

MATERIALS

Refer to Division 700.

CONSTRUCTION METHODS

Construct the subgrade and approach fills in accordance with the contract.

Apply Section 552 to all concrete except as otherwise provided herein. Use 4500 psi concrete.

Apply a broomed texture to the approach slabs before the concrete becomes non-plastic. Cure bridge approach slabs in the same manner as specified for bridge decks in Section 552.

Temporarily cover or fill the opening in the joint at the abutment until installation of the joint seal, if applicable. Make sure that the covering or filler provides for drainage off the bridge deck and keeps debris out of the joint and off the abutment cap.

When shown in the plans, construct sidewalks on bridge approach slabs in accordance with plan details. Finish the concrete in accordance with Section 552.

Construct temporary slope drains in accordance with Section 157.11. Locate this erosion control item as shown in the Structure plan detail.

Backfill around the approach slabs as soon as practical to prevent erosion adjacent to the slab.

MEASUREMENT AND PAYMENT

There will be no separate pay item for the bridge approach slabs. The cost for all items required to construct bridge approach slabs including, but not limited to, those items contained in the description of work shall be included in the various pay items.

Temporary Slope Drains shall be considered incidental to this work.

POWDER COATED PEDESTRIAN RAIL

DESCRIPTION

This work shall consist of powder coating new steel pedestrian railing (including all rails, posts, above ground hardware, etc.) in powder coating shop facilities. This works shall also include supplying new steel rail materials and hardware, fabrication and construction of rail sections, delivery of finished rail to project location and installation of finished rail on bridge.

MATERIALS

Galvanizing:

The steel pedestrian rail shall be galvanized in accordance with the provisions of Section 717.07, and meet the following additional requirements.

· Hot-dipped galvanized components to be powder-coated shall not receive a water quench or chromate quench.

· All drainage spikes and surface defects shall be removed.

· Galvanized components shall not be left outside or allowed to get wet.

· Galvanized components shall not be transported uncovered.

Surface Preparation:

If contamination of the galvanizing has occurred or is suspected, the galvanizing shall be cleaned with a solvent/detergent designed for pre-cleaning and completely rinsed off prior to powder-coating. Solvents should only be applied with lint-free rags or soft bristled nylon brushes. Once rinsed, the components must be allowed to completely air dry.

If ash residue from galvanizing is present, it should be removed using a solution of one to two percent ammonia. Apply the ammonia solution with a nylon brush, rinse thoroughly with hot water and allow the galvanizing to dry completely.

All surfaces to be painted shall be pressure washed, using equipment operating at a minimum pressure of 3000 psi, and a minimum flow of 4 gal/minute. The nozzle shall be held at a distance of 6” to 12” from the surface.

When the washing is completed, the cleaned surfaces shall be free of dust, dirt, oil and grease, animal waste, salts, and other debris. Oil and grease shall be removed by solvent cleaning. The areas shall be pressure washed again following this cleaning.

Once cleaned, all galvanized surfaces shall receive a light sweep blast using abrasive blasting equipment. All compressed air used to satisfy the requirements of this specification shall be clean. The cleanliness shall be verified with a white blotter test according to ASTM D4285 at least once per shift. The light blast shall remove zinc oxides from the galvanizing and etch the surface. The sweep blast shall impart to the galvanized surface an anchor profile of 1 to 1-1/2 mils as measured using profile tape and a spring loaded micrometer in accordance with ASTM D4417.

The initial thickness of the galvanizing prior to sweep blasting shall be established using a magnetic thickness gage, in a manner as described under ASTM A123. If the sweep blast results in a 15% or greater loss of galvanized coating, the article shall be rejected.

The sweep blast shall be performed in a manner that does not result in disbondment or flaking of the galvanizing. After sweep blasting, the galvanized surfaces shall be thoroughly blown down with clean compressed air to remove all blast residues. Any sharp, protruding defects in the galvanized surface, such as that commonly found on edges and holes, shall be removed by hand tools.

Powder Coating:

The pedestrian rail shall be powder coated in a powder coating facility (“shop”).

Application of the powder coating shall be performed within 12 hours of sweep blasting the galvanized surface. If more than 12 hours elapse prior to coating, the galvanized surfaces shall be re-blasted. If re-blasted, the item shall not have lost 15% or more of its original galvanized coating thickness.

Exterior surfaces of the railing shall be coated with a urethane or triglycidyl Isocyanurate (TGIC) polyester powder of a degassing grade only to a minimum dry film thickness of 4 mils

All galvanized components to be powder coated shall be preheated in an oven to the temperature recommended by the manufacturer of the powder coat to avoid pinholing during powder cure.

The coating shall be electrostatically applied and cured in a gas fired convection oven by heating the coated components to a specified temperature, and holding that temperature for a duration of time as recommended by the manufacturer of the powder coat (see Product Data Sheet for powder coat) to ensure sufficient storing time to meet curing specifications of the powder. Adjust pre-heating and line speed to ensure full cure.

The manufacturer’s inspector shall check for correct cure by solvent testing. The powder coating shall achieve a minimum hardness of 2H as per ASTM D3363. It shall be capable of withstanding an impact test of 130 lb-ft as per ASTM D2794 without any sign of cracking or lack of adhesion.

The powder coating for exterior surfaces shall be colored as shown in contract document. A color chip of 3” x 3” or greater shall be provided to the EIC no less than 2 weeks prior to coating for approval.

Damaged Coating

Powder coated articles shall be carefully transported to the work site in such a manner as to prevent any damage to the coating. Woven straps shall be used to unload the articles and they shall be carefully placed on timber donnage while awaiting installation. Powder coated articles that arrive at the worksite with damage to the coating greater than 1” (in any dimension) and/or extending to the galvanized coating will be rejected. Powder coated articles that are damaged while awaiting installation or are damaged during installation shall be subject to the same restrictions/requirements. The Contractor shall return to the shop such articles for cleaning and powder coating at no additional cost to the Owner. The cleaning procedure shall not remove galvanizing excessively as noted in this specification. Damage to the coating that is 1” or smaller shall be repaired in the field using surface preparation techniques and repair material recommended by the powder coating manufacturer. The manufacturer’s recommendations shall be followed in the application and curing of the repair material.

If the damage to the coating is smaller than 1” but has occurred at numerous locations on an article such that the Engineer believes the aesthetic value of the coating has been compromised, then this article will be rejected and returned by the Contractor to the shop for powder coating (as described earlier) at no cost to the Owner.

MEASUREMENT AND PAYMENT

The quantity to be measured for payment will be the linear foot of pedestrian railing that is powder coated and as described in the work contained in this special provision. The lump sum price bid will include all labor, material and equipment necessary to satisfactorily complete the work.

Powder Coated Pedestrian Rail _______ will be paid at the linear foot price.

STONE MASONRY VENEER

SECTION 1 - DESCRIPTION

This work shall consist of constructing stone masonry veneer fascia on the concrete bridge posts as shown on the project plans. Before construction, the stone veneer to be used shall be approved by the USDA Forest Service (owner). The construction of the concrete posts is not covered by the work of this section.

General

Wherever this provision fails to cover work included in the above description, reference is made to Section 556 of the Standard Specifications.

This Special Provision further specifies requirements for natural stone composite veneer to be placed on the bridge post faces but not limited to, the following:

· Veneer for composite wall construction.

· Masonry anchors, ties and accessories.

· Portland Cement-Lime (PCL) Mortar.

Submittals

Shop Drawings: Provide shop drawings showing general setting layout including pertinent dimensions, anchorages and jointing methods.

Samples: If on-site materials are not being used, submit representative samples for each material as follows. Delivered materials shall closely match accepted samples.

· Veneer: Submit a minimum of four samples showing extreme variation which may reasonably occur in each kind of stone regarding size, color, texture and quality.

Product Data: Submit product data of materials and systems to be used as masonry accessories. Include manufacturer's test data, installation instructions, use limitations, and recommendations for each material used.

Test Results: Submit certified test results of ASTM standards specified prior to commencing associated work. Submit mortar mix design report including description of contents, proportions and results of tests specified. Provide independent laboratory analysis of mortar materials.

Proposed Construction Practices: If cold weather or hot weather masonry work is anticipated, submit methods proposed to show compliance with cold-weather and hot-weather procedure requirements of ACI 530.1/ASCE 6.

Mock-up: Prior to commencing primary work of this Special Provision, construct a 4’ x 4’ square mock-up of a composite wall and obtain the owner’s acceptance of visual qualities. Mock-up shall include an 8 inch thick concrete back-up wall with composite veneer, including ties and anchors. The top 1’ of the wall shall consist of a 12 inch thick concrete wall with no stone veneer to provide a test area for color testing of compatible colored concrete sealers. Mock-up shall be constructed at a location acceptable to owner. Protect and maintain mock-up throughout construction of rails and wing walls to serve as criteria for acceptance of work.

· The mock-up shall demonstrate the coursing, anchorage and placement of the composite veneer to the concrete back-up wall. Mock-up wall shall also be used to demonstrate application of anti-graffiti coating.

· Demolish and remove the mock-up sample from the site when directed to do so by the owner.

Installer Qualifications: Submit a list and photographs of five similar projects completed in the last three years with project names, locations, names and addresses of project architects and owners to demonstrate capabilities and expertise installing stone masonry veneer similar in material, design and extent.

Standards

Veneer required by this Special Provision shall be the product of a single quarry. Provide secondary materials which are acceptable to the stone supplier.

Engage an experienced installer who has completed stone masonry veneer similar in material, design and extent to that indicated for this Project and with a record of successful in-service performance.

Testing

Veneer: Contractor is responsible for testing and quality control implementation of materials as specified herein (if additional veneer is required).

Mortar: Perform mortar testing in accordance with ASTM C 270, Method A-7, 2 inch cubes. Perform retest if initial test fails.

Project Conditions

Hot Weather Protection: Hot weather construction is defined as occurring when ambient temperatures exceed 100oF or 90oF when wind velocity is greater than 8 mph. Monitor mortar temperature and maintain it between 70oF and 120oF. Use mortar within 2-1/2 hours after mixing. Discard mortar over 2-1 /2 hours old and mortar stiffened due to hydration (setting). Limit spreading of bed mortar to 4 feet (maximum) and place units within I minute of spreading mortar.

Cold Weather Protection: Cold weather construction is defined as occurring when ambient temperatures fall below 40oF or when the temperature of masonry units is below 40o F. Strictly comply with Cold Weather Masonry Construction and Protection Recommendations, and Recommended Practices & Guide Specifications for Cold Weather Masonry Construction, Portland Cement Association.

Protection: As the work progresses, continuously protect stonework and items which could be stained by mortar. Cover walls at end of each day’s work. Extend cover 24 in. down sides of walls and hold securely in place. Turn scaffold boards on edge at end of day and protect base of wall to prevent rain splashed mud or mortar from contacting masonry.

Loading: Do not apply loads until work has set and cured and is ready to accept loading.

Product Delivery, Storage and Handling

Materials shall be delivered, stored, and handled fully protected from wetting, staining, chipping, and other damage. Store masonry materials on raised timber or platforms, above ground, under weather tight covers or indoors, and keep clean and dry. Separate units from one another by wood strips or wedges. Store veneer so that markings corresponding to the setting drawings are easily discernible.

Deliver and store cement, lime, and other perishable materials in their original containers, plainly marked with brand name and manufacturer's name, indoors or in weather tight sheds.

Protect metal accessories from elements. Immediately before placing, remove loose rust, dirt, and other foreign materials.

SECTION 2 – MATERIALS

Veneer

Utilize on-site stone as the source material for this work. Use of other veneer source shall be approved in writing by CO and shall consist of materials, sizes and colors as approved by the Owner

Type: The stone selection for the bridge rail posts shall have the following characteristics:

· Color: As approved by the Owner.

· Cut: As approved by the Owner.

· Finish: As approved by the Owner.

Veneer shall be completely cut and finished before delivery, except as necessary for final fitting.

Portland Cement-Lime (PCL) Mortar

Portland cement: ASTM C 150, Type I, II or III except if used for cold weather conditions. Utilize Type III cement for cold weather conditions. The maximum percent of alkalies shall be 0.60. Air-entraining cement is not permitted. The use of blended cements, including Portland blast-furnace slag cement, Portland-pozzolan cement, slag cement and natural cement is not permitted.

Hydrated Lime: ASTM C 207, hydrated, Type S.

Mortar Aggregate: Complying with ASTM C 144, well graded and free of gypsum.

Water: Clean, potable.

The following ingredients shall not be used:

· Antifreeze additives.

· Calcium Chloride, Thyocyanates or other materials containing chloride ions.

· Ready mix mortar (ASTM C 1142).

· Masonry Cement.

· Other admixtures without the prior approval of the Owner.

Factory Pre-blended PCL mortar mixes shall comply with ASTM C 270, Type M, Property Method using component materials listed above. Limit air content to 10% (Maximum). Blend cementitious materials, aggregate, and admixtures under factory controlled conditions, which require only the addition of water at the project site. Oven dry aggregates prior to measuring and inclusion in the pre-blended mix.

Ties and Anchors

Veneer to Concrete back-up wall: Provide vertically adjustable dovetail type units for veneer/concrete composite wall construction.

· Dovetail triangular ties shall consist of a 12 gage dovetail clip with a 3/16 inch pivoting wire tie. Corrugated dovetail ties shall not be used. Wire ties shall be produced from cold drawn stainless steel wire conforming to ASTM A 580, Type 304. Wire tie length shall be as recommended by manufacturer for wall which gives minimum of 5/8 in. cover on exterior face of stone veneer.

· Dovetail anchor slots shall be minimum 20 gage stainless steel plate conforming to ASTM A 167, Type 304. Slots shall be supplied foamed filled to protect slot during concrete forming and placement.

Miscellaneous Materials

Masonry Cleaning Materials: Provide one of the following products as applicable for cleaning mortar stains, job dirt, and job stains from masonry work:

· Cleaning Material for Dark Colored Masonry:

· Sure Klean 600 Detergent; ProSoCo, Inc., Kansas City, KS

· New Masonry Detergent, Diedrich Technologies Inc., Oak Creek, WI

· NMD-80, EaCO Chem Inc., New Castle, PA

· Cleaning Material for Light Colored Masonry:

· Sure Klean 101 Lime Solvent; ProSoCo, Inc., Kansas City

· 200 Lime Solv, Diedrich Technologies Inc., Oak Creek, WI

· SafeRestore, EaCO Chem Inc., New Castle, PA

Ant-Graffiti Coating: Anti-graffiti coating shall be permanent and invisible. Coating shall dry to a matte or satin, not glossy finish. Anti-graffiti coating product shall be compatible with the stone veneer used on the wing walls and rails.

SECTION 3 - CONSTRUCTION METHODS

Masonry Construction - General

Masonry work shall be done by skilled masons, fully instructed as to requirements of this Specification, and adequately supervised during Work.

Cold weather masonry shall conform to Cold Weather Masonry Construction and Protection Recommendations, and IMI Recommended Practices & Guide Specifications for Cold Weather Masonry Construction and the following:

· Do no masonry work when outdoor temperature is less than 40°F unless provisions are made to adequately protect materials and finished work from frost by heating materials, enclosing work, and heating enclosed spaces.

· If masonry work must be done when ambient temperature is freezing or below, all masonry material must be at temperature between 50°F and 90°F, and mortar, when used, shall have a temperature between 60°F and 80°F. In addition, all masonry shall be protected from temperatures below 40°F for at least 48 hours after being laid.

Verify substrate that will accept stone work is true and plumb and constructed to the specified dimensions prior to beginning installation of stone veneer.

Mortar

Mix mortar materials a minimum of 5 minutes, but not more than 10 minutes. Adjust consistency to satisfaction of mason subject to compliance with specified criteria. Comply with Brick Industry Association Standard M1-88.

If mortar begins to stiffen, it may be re-tempered in accordance with ASTM C 270, Subparagraph 7.4.

Veneer Work

Erect stone in accordance with stone supplier’s instructions and shop drawings. Lay masonry plumb, true to line, and with level courses, with straight, clean, uniform joints, and true surfaces, and plumb corners. Maintain vertical alignment of joints as required by bond patterns indicated. Lay units in solid partitions to provide same evenness of surface on each side. Head and bed joints shall be approximately 3/8 inches wide.

Place setting buttons and set stone in full mortar setting bed to support stone over full bearing surface and to establish joint dimensions.

Adjust each masonry unit in final position while mortar is still soft and plastic. Remove units disturbed after mortar has stiffened. Clean off original mortar and re-lay with fresh mortar.

To accommodate pointing mortar, rake out joints 5/8 inch to 3/4 inch. Brush mortar joints clean.

Fill joints with pointing mortar. Pack and work into voids. Neatly tool surfaces to a concave, joint.

Provide chases, slots, and recesses as required to accommodate work of other trades. Close only after such work has been installed, tested, and approved. As work progresses, set anchors, bolts and frames required to be built into masonry. No cutting and patching of completed masonry will be permitted except as acceptable to Owner.

Install flashing of longest possible lengths at base course of veneer on interior face of rail post faces and at first coarse above grade for exterior face of rail post faces. Lap end joint a minimum of 6 inches and seal to a watertight condition.

Install cavity vents in vertical joints immediately above horizontal flashing and at top of cavity spaces to provide cavity venting.

Do not use installed masonry work to support or in any way receive scaffolding or other temporary supports.

Maintain masonry clean as work progresses. Exercise extreme care at exposed work to prevent smearing or staining with mortar.

At completion of work, cut out and rejoint holes and defective joints, leaving entire work free of blemishes.

Contractor is responsible for adequately bracing all masonry work during construction.

Tie and Anchor Installation General: Provide at least one tie for every 2.66 sq. ft. of wall area unless more frequent spacing is indicated or required. Do not space ties more than 2 ft. on center vertically or horizontally. Provide ties within 12 in. of wall openings and within 12 in. of wall perimeters and corners. Seal all penetrations with mastic.

Install dovetail anchor slots into formwork for concrete back-up wall prior to placing concrete. After concrete placement and removal of forms, remove foam fill in anchor slots as required to allow installation of dovetail triangular ties. Adjust triangular ties vertically to correspond with horizontal mortar joints of stone work.

Stoning and Cleaning Soon after masonry work is completed, lightly stone down exposed surfaces of masonry to remove excess mortar and aggregate projections.

Upon completion, thoroughly clean exposed exterior masonry with a solution of specified detergent and water, using stiff fiber brushes. Rinse surfaces cleaned with detergent as recommended by detergent manufacturer. Protect adjacent surfaces that are not to be cleaned. Cleaners or other solutions which may cause discoloration or damage will not be permitted. Muriatic acid is not permitted.

· Prior to applying any cleaning materials on finished masonry work, provide a test cleaning mock-up on masonry mock-up at locations acceptable to the Owner.

· Test the cleaning techniques and solutions to determine the best methods for the conditions encountered. Demonstrate Contractor's quality control system to ensure uniform final appearance. Test adjacent non-masonry surfaces for possible adverse reactions to cleaning methods. Use all cleaning products in strict compliance with the manufacturers' instructions and recommendations. Keep accurate, detailed records of concentrations, solutions, and techniques used to assist in replicating satisfactory results.

Rake out imperfect mortar joints of masonry work and repoint to match appearance of surrounding acceptable work. Leave entire work free of defects.

Tolerances

Maximum variation form plumb for vertical lines and surfaces of wing walls and rail faces:

· 1/4 inch in 10 feet but not to exceed 3/8 inch in overall height of wing walls or rail faces.

Maximum variation in cross section dimensions and thicknesses of walls from plan dimensions shown:

· Minus 1/4 inch; plus 1/2 inch.

Maximum variation from joint thickness:

· Minus 1/8 inch in 3 feet; 1/4 inch in 10 feet; 1/2 inch maximum.

Maximum variation from level coursing:

· Minus 1/8 inch in 3 feet or 1/4 the joint width, whichever is less.

Anti-Graffiti Coating Application

Follow manufacturer’s recommendations for surface preparation, application rate and methods. Do not damage stone veneer.

Do not allow drips or overspray to contaminate untreated surfaces adjacent to treated surfaces.

SECTION 4 - MEASUREMENT AND PAYMENT

Method of Measurement

Stone Masonry Veneer will be paid for at the lump contract price of acceptable stone masonry veneer installed on the concrete posts as shown on the plans. The cost of constructing the concrete bridge posts is not covered by the work of this section.

Stone Masonry Veneer _______ will be paid at the contract lump sum price.

Basis of Payment

Payment of stone masonry veneer as installed on the concrete posts shall be full compensation for all materials, labor tools, equipment, testing, inspection, services and incidentals necessary to perform the work of this section and as shown on the project plans. Payment for this work shall also include furnishing and installing Portland cement-lime mortar, all masonry accessories and anti-graffiti coating.