SECTION 03315-DB STRUCTURES (BRIDGES, MSE WALLS & I … Packages/Coping...track in the existing I-10 box. Unless otherwise indicated or a Caltrans Standard Detail is called for in

Exposition LRT Project Phase 2 02/20/2013APPROVED FOR CONSTRUCTION

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SECTION 03315-DB

STRUCTURES (BRIDGES, MSE WALLS & I-10 RCB SLAB)

STRUCTURES (BRIDGES, MSE WALLS & I-10 RCB SLAB) 03315-DB - 1

PART 1 – GENERAL

1.1 DESCRIPTION

The following items of work are covered in these specifications for the construction of Bundy, Bridge,Centinela Bridge, Motor Bridge, Olympic Bridge, Palms Bridge, Pico Bridge and Sepulveda Bridge,Retaining Walls RW 508R, RW 508L, RW 644R, RW 645L, RW 654R, RW 655L, RW 676R, RW 677L,RW 700, RW 712, RW 726, RW 766R, RW 767L, RW 778R and RW 779L, and the concrete slab for thetrack in the existing I-10 box. Unless otherwise indicated or a Caltrans Standard Detail is called for in theapproved drawings, appurtenances attached to the bridge structure are not covered by this Section, andshall conform to their respective Sections.

1.2 QUALITY CONTROL

A. Comply with General Requirements Section 01460, Project Quality Management Programrequirements.

1.3 REFERENCES

A. Metro Rail Design Criteria

B. State of California Standard Specifications 2010.

1.4 SUBMITTALS - Refer to General Requirements Section 01300, Submittals, for submittalprocedures.

A. Submittals required in accordance with General Requirements Section 01460, ProjectQuality Management Program requirements.

B. For Concrete Lift Drawings submittal requirements see Section 03300-1.4D.

PART 2 – PRODUCTS

Included in the attached specifications for various items of work

PART 3 – EXECUTION

Included in the attached specifications for various items of work


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DIVISION I GENERAL PROVISIONS...................................................................................................... 5

1 GENERAL ........................................................................................................................................... 5

DIVISION II GENERAL CONSTRUCTION ............................................................................................ 11

10 GENERAL ....................................................................................................................................... 11

11 QUALITY CONTROL AND ASSURANCE ........................................................................................ 11

12 TEMPORARY TRAFFIC CONTROL ................................................................................................ 15

13 WATER POLLUTION CONTROL ..................................................................................................... 15

14 ENVIRONMENTAL STEWARDSHIP ................................................................................................ 15

15 EXISTING FACILITIES .................................................................................................................... 15

DIVISION III GRADING......................................................................................................................... 16

16 CLEARING AND GRUBBING .......................................................................................................... 16

17 WATERING ..................................................................................................................................... 16

18 DUST PALLIATIVE .......................................................................................................................... 17

19 EARTHWORK ................................................................................................................................. 17

20 LANDSCAPE ................................................................................................................................... 29

21 EROSION CONTROL ...................................................................................................................... 29

22 FINISHING ROADWAY.................................................................................................................... 29

23 NOT USED ...................................................................................................................................... 29

DIVISION IV SUBBASES AND BASES ................................................................................................. 29

24 STABILIZED SOILS ......................................................................................................................... 29

25 AGGREGATE SUBBASES .............................................................................................................. 29

26 AGGREGATE BASES ..................................................................................................................... 29

27 CEMENT TREATED BASES ............................................................................................................ 31

28 CONCRETE BASES ........................................................................................................................ 31

29 TREATED PERMEABLE BASES ..................................................................................................... 31

30-36 NOT USED ................................................................................................................................. 33

DIVISION V SURFACING AND PAVEMENTS ...................................................................................... 33

37 BITUMINOUS SEALS ...................................................................................................................... 33

38 NOT USED ...................................................................................................................................... 33

39 HOT MIX ASPHALT ......................................................................................................................... 33

40 CONCRETE PAVEMENT ................................................................................................................ 33

41 CONCRETE PAVEMENT REPAIR................................................................................................... 39

42 GROOVE AND GRIND CONCRETE ................................................................................................ 39

43–45 NOT USED ................................................................................................................................ 39


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DIVISION VI STRUCTURES ................................................................................................................ 39

46 GROUND ANCHORS AND SOIL NAILS.......................................................................................... 39

47 EARTH RETAINING SYSTEMS ...................................................................................................... 40

48 TEMPORARY STRUCTURES ......................................................................................................... 45

49 PILING ............................................................................................................................................ 55

50 PRESTRESSING CONCRETE ........................................................................................................ 75

51 CONCRETE STRUCTURES ........................................................................................................... 83

52 REINFORCEMENT ....................................................................................................................... 128

53 SHOTCRETE ................................................................................................................................ 146

54 WATERPROOFING ...................................................................................................................... 146

55 STEEL STRUCTURES .................................................................................................................. 148

56 SIGNS ........................................................................................................................................... 164

57 WOOD AND PLASTIC LUMBER STRUCTURES .......................................................................... 165

58 SOUND WALLS ............................................................................................................................ 165

59 PAINTING ..................................................................................................................................... 165

60 NOT USED.................................................................................................................................... 173

DIVISION VII DRAINAGE ................................................................................................................... 173

61 CULVERT AND DRAINAGE PIPE JOINTS .................................................................................... 173

62 ALTERNATIVE CULVERTS .......................................................................................................... 173

63 NOT USED.................................................................................................................................... 173

64 PLASTIC PIPE .............................................................................................................................. 173

65 CONCRETE PIPE ......................................................................................................................... 173

66 CORRUGATED METAL PIPE ....................................................................................................... 173

67 STRUCTURAL PLATE CULVERTS ............................................................................................... 180

68 SUBSURFACE DRAINS ................................................................................................................ 180

69 OVERSIDE DRAINS ..................................................................................................................... 184

70 MISCELLANEOUS DRAINAGE FACILITIES ................................................................................. 184

71 NOT USED.................................................................................................................................... 184

DIVISION VIII MISCELLANEOUS CONSTRUCTION.......................................................................... 184

72 SLOPE PROTECTION .................................................................................................................. 184

73 CONCRETE CURBS AND SIDEWALKS ....................................................................................... 184

74 PUMPING EQUIPMENT AND CONTROLS ................................................................................... 184

75 MISCELLANEOUS METAL ........................................................................................................... 184

76 WELLS .......................................................................................................................................... 197


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77 LOCAL INFRASTRUCTURE .......................................................................................................... 197

78–79 NOT USED .............................................................................................................................. 197

80 FENCES ........................................................................................................................................ 197

81 MONUMENTS ............................................................................................................................... 201

DIVISION IX TRAFFIC CONTROL FACILITIES .................................................................................. 201

82 MARKERS AND DELINEATORS ................................................................................................... 201

83 RAILINGS AND BARRIERS ........................................................................................................... 201

84 TRAFFIC STRIPES AND PAVEMENT MARKINGS ........................................................................ 209

85 PAVEMENT MARKERS ................................................................................................................. 209

86 ELECTRICAL SYSTEMS ............................................................................................................... 210

DIVISION X MATERIALS .................................................................................................................... 210

87 MATERIALS–GENERAL ................................................................................................................ 210

88 GEOSYNTHETICS ........................................................................................................................ 210

89 NOT USED .................................................................................................................................... 216

90 CONCRETE................................................................................................................................... 216

91 PAINT ............................................................................................................................................ 244

92 ASPHALTS .................................................................................................................................... 245

93 LIQUID ASPHALTS ....................................................................................................................... 245

94 ASPHALTIC EMULSIONS ............................................................................................................. 245

95 EPOXY .......................................................................................................................................... 245

96–98 NOT USED .............................................................................................................................. 248

DIVISION XI BUILDING CONSTRUCTION ......................................................................................... 248

99 BUILDING CONSTRUCTION ......................................................................................................... 248


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DIVISION I GENERAL PROVISIONS1 GENERAL

1-1.01 GENERALThe following items of work are covered in these specifications for the construction of Bundy, Bridge,Centinela Bridge, Motor Bridge, Olympic Bridge, Palms Bridge, Pico Bridge and Sepulveda Bridge,Retaining Walls RW 508R, RW 508L, RW 644R, RW 645L, RW 654R, RW 655L, RW 676R, RW 677L,RW 700, RW 712, RW 726, RW 766R, RW 767L, RW 778R and RW 779L, and the concrete slab for thetrack in the existing I-10 box.

Work Items and Applicable SectionsItemcode

Item description Applicablesection

192003 STRUCTURE EXCAVATION (BRIDGE) 19193003 STRUCTURE BACKFILL (BRIDGE) 19477020 MECHANICALLY STABILIZED EMBANKMENT 47480501 JACKING SUPERSTRUCTURE 48490601 16" CAST-IN-DRILLED-HOLE CONCRETE PILING 49490603 24" CAST-IN-DRILLED-HOLE CONCRETE PILING 49490618 96" CAST-IN-DRILLED-HOLE CONCRETE PILING 49500001 PRESTRESSING CAST-IN-PLACE CONCRETE 50510050A STRUCTURAL CONCRETE, STATION PLATFORM 51510050B STRUCTURAL CONCRETE, WALKWAY 51510050C STRUCTURAL CONCRETE, SLAB TRACK 51510051 STRUCTURAL CONCRETE, BRIDGE FOOTING 51510053 STRUCTURAL CONCRETE, BRIDGE 51510072 STRUCTURAL CONCRETE, BARRIER SLAB 51510080 STRUCTURAL CONCRETE, APPROACH SLAB 51511035 ARCHITECTURAL TREATMENT 51511106 DRILL AND BOND DOWEL 51512277 FURNISH PRECAST PRESTRESSED CONCRETE BULB-TEE GIRDER

(80'-90')51

512500 ERECT PRECAST PRESTRESSED CONCRETE GIRDER 51518050 PTFE BEARING 51519089 JOINT SEAL ASSEMBLY 51520101A BAR REINFORCING STEEL (STATION PLATFORM) 52520101B BAR REINFORCING STEEL (WALKWAY) 52520101C BAR REINFORCING STEEL (SLAB TRACK) 52520102 BAR REINFORCING STEEL (BRIDGE) 52520106 BAR REINFORCING STEEL (EPOXY COATED) 52520122 STRAY CURRENT PROTECTION (BRIDGE) 52540104 WATERPROOFING AND COVER 54550102 STRUCTURAL STEEL (BRIDGE) 55681132 GEOCOMPOSITE DRAIN 68750498 MISCELLANEOUS METAL (RESTRAINER - CABLE TYPE) 75750501 MISCELLANEOUS METAL (BRIDGE) 75750505 BRIDGE DECK DRAINAGE SYSTEM 75839401 CONCRETE BARRIER 83839514 HANDRAILING 83839527 CABLE RAILING (MODIFIED) 83


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1-1.02 ABBREVIATIONSInterpret the meaning of an abbreviation used in these specifications as shown in the following table:

AbbreviationsAbbreviation MeaningAASHTO American Association of State Highway and Transportation OfficialsAB aggregate baseACI American Concrete InstituteAISC American Institute of Steel ConstructionAISI American Iron and Steel InstituteAMA archaeological monitoring areaANSI American National Standards InstituteAPI American Petroleum InstituteAREMA American Railway Engineering and Maintenance-of-Way AssociationAS aggregate subbaseASME American Society of Mechanical EngineersASQ American Society for QualityATPB asphalt treated permeable baseAWG American Wire GaugeAWPA American Wood Protection AssociationAWS American Welding Societya

AWWA American Water Works AssociationBBS battery backup systemBNSF Burlington Northern Santa FeCal/OSHA California Division of Occupational Safety and Health AdministrationCBC California Building CodeCDPH California Department of Public HealthCIDH cast-in-drilled-holeCIH Certified Industrial HygienistCIP cast in placeCJP complete joint penetrationCMU concrete masonry unitCPM critical path methodCPL composite plastic lumberCRCP continuously reinforced concrete pavementCRM crumb rubber modifierCTB cement treated baseCTPB cement treated permeable baseCVN Charpy V-notchCWI AWS Certified Welding InspectorDBE Disadvantaged Business EnterpriseDRA Dispute Resolution AdvisorDRB Dispute Resolution BoardDTSC Department of Toxic Substances ControlDVBE Disabled Veteran Business EnterpriseECTC Erosion Control Technology CouncilEIA Electronic Industries AllianceESA environmentally sensitive areaETL Electrical Testing Laboratoriesfc extreme fiber compressive stress in concrete at service loadsf'c compressive strength of concreteFHWA Federal Highway AdministrationGAAP Generally Accepted Accounting PrinciplesGGBFS ground granulated blast furnace slag; slag cement


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GSP galvanized steel pipeHMA hot mix asphaltHMA-O hot mix asphalt (open graded)HS high strengthICC International Code CouncilITE Institute of Transportation EngineersIEEE Institute of Electrical and Electronics EngineersJMF job mix formulaJPCP jointed plain concrete pavementksf kips per square footksi kips per square inchLCB lean concrete baseLEED Leadership in Energy and Environmental DesignLOTB log of test boringLTDS long term design strengthMC medium curingMPI Master Painters InstituteMR movement ratingMSDS material safety data sheetMT magnetic particle testingMUTCD Manual on Uniform Traffic Control DevicesNDT nondestructive testingNETA International Electrical Testing AssociationNEC National Electrical CodeNEMA National Electrical Manufacturers AssociationNFPA National Fire Protection AssociationNPDES National Pollutant Discharge Elimination SystemNPT National Pipe Thread TaperNRTL Nationally Recognized Testing LaboratoryOBC optimum binder contentOGFC open graded friction coursePLAC permit, license, agreement, certification, or any combination of thesePC precastPCC portland cement concretepcf pounds per cubic footPG performance gradePI0 zero blanking band profile indexPJP partial joint penetrationPQR procedure qualification recordPS prestressedPSF pedestrian signal facePV programmed visibilityRAP reclaimed asphalt pavementRCSC Research Council on Structural ConnectionsRECP rolled erosion control productRFI request for informationRHMA rubberized hot mix asphaltRHMA-G rubberized hot mix asphalt (gap graded)RHMA-O rubberized hot mix asphalt (open graded)RHMA-O-HB rubberized hot mix asphalt (open graded high binder)RPL recycled plastic lumberRSC rapid strength concreteRSP rock slope protectionRSS revised standard specifications


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RT radiographic testingRWQCB Regional Water Quality Control BoardSMSA Standard Metropolitan Statistical AreaSC slow curingSCC self-consolidating concreteSCM supplementary cementitious materialSRJV Skanska Rados joint ventureSSPC The Society for Protective CoatingsSWPPP storm water pollution prevention planTEES Transportation Electrical Equipment SpecificationsTIA time impact analysisTV target valueUDBE Underutilized Disadvantaged Business EnterpriseUFFA ultra fine fly ashUL Underwriters Laboratories, IncUSC United States CodeUSM unidentified stock materialUT ultrasonic testingVECP value engineering change proposalVPM volts per milWPCP water pollution control programWPS welding procedure specificationaInterpret a reference to AWS as a reference to AWS, ANSI/AWS, or AASHTO/AWS

1-1.03 DEFINITIONS1-1.03A GeneralInterpret terms as defined in these specifications .

1-1.03B Glossaryauthorized laboratory: Independent testing laboratory employed by SRJV authorized by the Authority.

Authorized Facility Audit List: A list of fabricator facilities audits completed by the CaliforniaDepartment of Transportation. The list is located athttp://www.dot.ca.gov/hq/esc/Translab/OSM/SMBAudits.htm

Authorized Material List: A list of materials prequalified by the California Department of Transportationfor use on projects. The list is located at http://www.dot.ca.gov/hq/esc/approved_products_list/

bridge: Structure that carries a utility or railroad or vehicle, pedestrian, or other traffic over, under, oraround obstructions or waterways

California Test: Department-developed test for determining work quality. For California Tests, go to theMETS Web site.

Caltrans: California Department of Transportation as defined in St & Hwy Code § 20 and authorized in St& Hwy Code § 90; its authorized representatives.

certificate of compliance: Certificate stating the material complies with these specifications .

Certified Industrial Hygienist: Industrial hygienist certified in comprehensive practice by the AmericanBoard of Industrial Hygiene.

commercial quality: Quality meeting the best general practices.

commercial source: Established business operating as a material source to the general public.


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Contract: The term “Contract” for these specifications refers to the work required for the construction ofBundy, Bridge, Centinela Bridge, Motor Bridge, Olympic Bridge, Palms Bridge, Pico Bridge andSepulveda Bridge, Retaining Walls RW 508R, RW 508L, RW 644R, RW 645L, RW 654R, RW 655L,RW 676R, RW 677L, RW 700, RW 712, RW 726, RW 766R, RW 767L, RW 778R and RW 779L, andthe concrete slab for the track in the existing I-10 box in conformance with the plans and thesespecifications.

Department: The SRJV and/or the Authority based on the requirements of the Design Build Contract No.XP8902-002 Exposition LRT Project Phase 2.

dispose of: Remove from the job site.

Engineer: The SRJV and their designer of record.

job site: Area within the defined boundaries of a project.

material: Any product or substance specified for use in the construction of a project.

material source facility audit: Self-audit and a Department audit evaluating a facility's capability toconsistently produce materials that comply with Department standards.

METS: The term “METS” for these specifications refers to the independent testing laboratory employedby SRJV authorized by the Authority.

METS Web site: The California Department of Transportation Materials Engineering and TestingServices web site located at http://www.dot.ca.gov/hq/esc/Translab/

plans: Standard plans, revised standard plans, and project plans.

1. standard plans: Drawings standard to Department construction projects.2. revised standard plans: New or revised standard plans.3. project plans: Drawings specific to the project, including authorized shop drawings.

quality control plan: The SRJV project quality management plan and procedures.

roadside: Area between the outside shoulder edge and the right-of-way limits.

roadway: That portion of the highway within the outside lines of curbs, sidewalks, slopes, ditches,channels, or waterways. Roadway includes structures and features necessary for safety, protection offacilities, and drainage.

small tool: Tool or piece of equipment not listed in Labor Surcharge and Equipment Rental Rates thathas a replacement value of $500 or less.

specifications: Standard specifications, revised standard specifications, and special provisions.

1. standard specifications: The California Department of Transportation 2010 Standard Specifications.2. specifications: These specifications.

State: The State of California, including its agencies, departments or divisions whose conduct or action isrelated to the work.

Structure Design (ODS): The term “Structure Design (ODS)” for these specifications refers to the SRJVstructures designer of record.

submittal:

1. action submittal: Written and graphic information and samples that require the Department'sresponse.

2. informational submittal: Written information that does not require the Department's response.


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substantial defects: Defects plainly seen as damaged, displaced, or missing parts or improperfunctioning of materials, parts, equipment, or systems.

substructure: Bridge parts below the bridge seats, pier tops, and haunches for rigid-framed bridges orspring lines for arched bridges; includes abutment backwalls, abutment parapets, and wingwalls.

superstructure: Bridge parts except the substructure.

traffic: Pedestrians, bicyclists, ridden or herded animals, vehicles, streetcars, and other conveyanceseither singularly or together while using any highway for purposes of travel.

traffic lane: Portion of traveled way used for the movement of a single line of vehicles.

traveled way: Roadway portion for the movement of vehicles except shoulders.

the Authority: Exposition Metro Line Construction Authority

Transportation Laboratory: The term “Transportation Laboratory” for these specifications refers to theindependent testing laboratory employed by SRJV authorized by the Authority.

unauthorized work: Work performed beyond the lines and grades described in the plans and thesespecifications or extra work performed without authority.

work: Resources and activities required for the construction of Bundy, Bridge, Centinela Bridge, MotorBridge, Olympic Bridge, Palms Bridge, Pico Bridge and Sepulveda Bridge, Retaining Walls RW 508R,RW 508L, RW 644R, RW 645L, RW 654R, RW 655L, RW 676R, RW 677L, RW 700, RW 712, RW726, RW 766R, RW 767L, RW 778R and RW 779L, and the concrete slab for the track in the existingI-10 box.

work plan: Detailed formulation of a program of action.

work zone: Area of a highway with construction, maintenance, or utility work activities.


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DIVISION II GENERAL CONSTRUCTION10 GENERAL

Not Used

11 QUALITY CONTROL AND ASSURANCE11-1 GENERAL

11-1.01 GENERALSection 11 includes specifications relating to quality control and assurance.

11-1.02 QUALITY CONTROL MANAGERWhere a QC manager is specified, assign a QC manager before starting construction activities. The QCmanager must be the sole individual responsible for:

1. Receiving, reviewing, and approving all correspondence, submittals, and reports before they aresubmitted to the Department

2. Signing QC plans3. Implementing QC plans4. Maintaining QC records

The QC manager must be responsible directly to you for the quality of the work, including materials andworkmanship performed by you and your subcontractors.

The QC manager must be your employee or must be hired by a subcontractor providing only QCservices. The QC manager must not be employed or compensated by a subcontractor or by otherpersons or entities hired by subcontractors who will provide other services or materials for the project.

Notify the Engineer of the name and contact information of the QC manager.

11-2 PRECAST CONCRETE MEMBERS11-2.01 GENERALSection 11-2 applies to PC concrete members fabricated under sections 49 or 51 excluding PC concretemembers fabricated with minor concrete.

Fabricate PC concrete members at a plant on the Authorized Facility Audit List.

11-2.02 PRECAST CONCRETE QUALITY CONTROL MANAGERAssign a PC concrete QC manager for each precasting plant.

11-2.03 QUALITY CONTROL INSPECTORThe QC inspector must witness all PC concrete activities.

The QC inspector must either (1) be registered as a civil engineer in the State or (2) have a current PlantQuality Personnel Certification, Level II from the Precast/Prestressed Concrete Institute.

The QC inspector must perform inspection and testing before precasting, during precasting, and afterprecasting, as specified and as necessary to ensure that materials and workmanship comply with theContract.

Regardless of your acceptance of a PC concrete member, the Engineer inspects PC concrete membersand rejects any members that do not comply with the Contract.

11-2.04 SUBMITTALS11-2.04A GeneralBefore submitting the PC concrete QC plan, hold a meeting to discuss the requirements for PC concreteQC. The meeting attendees must include the Engineer, the PC concrete QC manager, and arepresentative from each plant performing PC concrete activities for the Contract.


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11-2.04B Precast Concrete Quality Control PlanBefore performing any precasting activities, submit 3 copies of a PC concrete QC plan for each memberto be precast. Submit a separate QC plan for each plant. Allow 10 days for the Engineer's review.

Each QC plan must include:

1. Name of the precasting plant, concrete plant to be used, and any concrete testing laboratory to beused.

2. Manual prepared by the precasting plant that includes equipment, testing procedures, safety plan,and the names, qualifications, and documentation of certifications for all personnel to be used.

3. Name of the QC manager and the names, qualifications, and documentation of certifications for allQC inspectors.

4. Organizational chart showing all QC personnel and their assigned QC responsibilities.5. Methods and frequencies for performing all required QC procedures, including all inspections,

material testing, and any required survey procedures for all components of the PC concrete membersincluding prestressing systems, concrete, grout, reinforcement, steel components embedded orattached to the PC concrete member, miscellaneous metal, and formwork.

6. System for reporting noncompliant PC concrete members to the Engineer.7. System for identification and tracking of any required repairs, how they were repaired, and a

procedure for the reinspection of any repaired PC concrete members.8. Forms to be used for certificates of compliance, daily production logs, and daily reports.

A QC plan that was previously authorized no more than 1 year before the start of job site activities on theContract is acceptable for the entire period of the Contract, if the Engineer determines the QC plan is forthe same type of work that is to be performed on the Contract.

Submit an amended QC plan or an addendum to the QC plan for any changes to:

1. Concrete plants or source materials2. Material testing procedures and testing labs3. Procedures and equipment4. Updated systems for tracking and identifying PC concrete members5. QC personnel

Submit 7 copies of each authorized QC plan and make 1 copy available at each location where work isperformed.

11-2.04C Daily Production LogThe QC inspector must provide reports to the QC manager on a daily basis for each day that precastingactivities are performed.

The QC manager must maintain a daily production log for precasting for each day that precastingactivities are performed, including setting forms, placing reinforcement, setting prestressing steel, casting,curing, post tensioning, and form release. This daily log must be available for viewing by the Engineer atthe precasting plant. The daily log must include:

1. Plant location2. Specific description of casting or related activities3. Any problems or deficiencies discovered4. Any testing or repair work performed5. Names of all QC inspectors and the specific QC inspections they performed that day6. Reports for that day's precasting activities from each QC inspector

Notify the Engineer immediately when any precasting problems or deficiencies are discovered and submitthe proposed repair or process changes required to correct them. Allow 25 days for the Engineer 'sreview.


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11-2.04D Precast Concrete ReportSubmit a PC concrete report within 15 days following the completion of any PC concrete member. Thereport must include:

1. Reports of all material tests and any required survey checks2. Documentation that you have evaluated all tests and corrected all rejected deficiencies, and all

repairs have been re-examined with the required tests and found acceptable3. Daily production logs4. Certificate of compliance signed by the QC manager. The certificate must state that all of the

materials and workmanship incorporated in the work and all required tests and inspections of thiswork, have been performed as described in the Contract.

The person who performed the material tests and required survey checks must sign all reports regardingthese tests and survey checks and furnish these reports directly to the QC manager for review andsignature before submittal to the Engineer. Corresponding names must be clearly printed or typed next toall signatures.

11-3 WELDING11-3.01 GENERAL11-3.01A GeneralSection 11-3.01 includes general specifications for welding where welding is specified to comply with anAWS welding code.

Do not perform welding using flux-cored welding electrodes that comply with AWS A5.20, E6XT-4 orE7XT-4.

Wherever reference is made to the following AWS welding codes in the Contract, the year of adoption forthese codes is shown in the following table:

AWS code Year of adoptionD1.1 2008D1.3 2008D1.4 2005D1.5 2008D1.6 2007D1.8 2009

11-3.01B Definitionscontinuous inspection: QC Inspector must be within close proximity of all welders or welding operators

so that inspections by the QC Inspector of each welding activity at each welding location does notlapse for a period exceeding 30 minutes.

gross nonconformance: Sum of planar type rejectable indications in more than 20 percent of the testedlength.

11-3.01C Quality Control InspectorReplace clause 6.1.3 of AWS D1.1, the 1st paragraph of section 7.1.2 of AWS D1.4, and clause 6.1.1.2 ofAWS D1.5 with:

The QC Inspector must be the duly assigned person who acts for and on your behalf for inspection,testing, and quality related matters for all welding.

Quality assurance is the prerogative of the Engineer. The QA Inspector is the duly designated personwho acts for and on behalf of the Engineer.

The QC Inspector must be responsible for QC acceptance or rejection of materials and workmanship. Where the term "Inspector" is used without further qualification, it refers to the QC Inspector.


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The QC Inspector must document inspection and approval of:

1. All joint preparations, assembly practices, joint fit-ups, welding techniques2. Performance of each welder, welding operator, and tack welder on a daily basis for each day welding

is performed

For each inspection, including fit-up, WPS verification, and final weld inspection, the QC Inspector mustconfirm and document compliance with AWS welding codes and the specifications on all welded jointsbefore welding, during welding, and after the completion of each weld.

11-3.01D Personnel Qualifications and CertificationsThe Engineer has the authority to verify the qualifications or certifications of any welder, QC Inspector, orNDT personnel to specified levels by retests or other means determined by the Engineer. The period ofeffectiveness for a welder's or welding operator's qualification must be a maximum of 3 years for thesame weld process, welding position, and weld type. If welding will be performed without gas shielding,then qualification must also include welding without gas shielding. Excluding welding of fracture criticalmembers, a valid qualification at the start of job site activities on a contract is acceptable for the entireperiod of the Contract, as long as the welder's or welding operator's work remains satisfactory.

Replace clause 6.14.6 of AWS D1.1, section 7.8 of AWS D1.4, and clause 6.1.3.4 of AWS D1.5 with:

Personnel performing NDT must be qualified and certified under American Society for NondestructiveTesting (ASNT) Recommended Practice No. SNT-TC-1A and the written practice of the NDT firm.The written practice of the NDT firm must comply with or exceed the guidelines of the ASNTRecommended Practice No. SNT-TC-1A. Individuals who perform NDT, review the results, andprepare the written reports must be one of the following:

1. Certified NDT Level II technicians2. Level III technicians who hold a current ASNT Level III certificate in that discipline and are

certified to perform the work of Level II technicians

11-3.01E Joint Weld DetailsIf joint weld details proposed for use in the work are not prequalified under clause 3 of AWS D1.1 or figure2.4 or 2.5 of AWS D1.5, submit the joint weld details, including their intended locations, weldingparameters, and essential variables.

Upon authorization of the proposed joint detail locations and qualification of the proposed joint details,welders and welding operators using these details must weld a qualification test plate using the WPSvariables and the joint weld detail to be used in production. The test plate must:

1. Have the maximum thickness to be used in production and a minimum length of 18 inches.2. Be mechanically and radiographically tested. Mechanical and radiographic testing and acceptance

criteria must comply with the applicable AWS codes.

If a nonstandard weld joint is to be made using a combination of WPSs for work welded under AWS D1.1,you may conduct a single test combining the WPSs to be used in production, if the essential variables,including weld bead placement, of each process are limited to those established in table 4.5 of AWSD1.1.

The Engineer will witness all procedure qualification tests for WPSs that were not previously authorizedby the Department.

Submit an inspection request form to the Engineer at least 7 days before performing any procedurequalification tests. Notify the Engineer of your submittal. Witnessing of qualification tests by the Engineerdoes not constitute authorization of the intended joint locations, welding parameters, or essentialvariables.

11-3.01F Nondestructive TestingReplace paragraph 3 of clause 6.26.3.2 of AWS D1.5 with:


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3. If indications that exhibit these planar characteristics are present at scanning sensitivity, orother evidence exists to suggest the presence of transverse cracks, a more detailed evaluationof the discontinuity by other means must be performed (e.g., alternate UT techniques, RT,grinding, or gouging for visual inspection or MT of the excavated areas.). For welds that havetransverse cracks, remove the metal for the full length of the crack plus 2 inches on each sideof the crack and reweld.

Clause 6.6.5 of AWS D1.1, section 7.6.5 of AWS D1.4, and clause 6.6.5 of AWS D1.5 do not apply.

The Engineer may order you to perform NDT that is in addition to the visual inspection or NDT specified inthe specifications or AWS welding code.

If less than 100 percent of NDT is specified for any weld, the entire length of weld must comply with thespecified acceptance criteria.

11-3.02 WELDING QUALITY CONTROL11-3.02A GeneralComply with Section 05055-DB Basic Welding Requirements.

12 TEMPORARY TRAFFIC CONTROLNot Used

13 WATER POLLUTION CONTROLNot Used

14 ENVIRONMENTAL STEWARDSHIPNot Used

15 EXISTING FACILITIES15-1 GENERAL

15-1.01 GENERALSection 15-1 includes general specifications for performing work on existing facilities.

Wherever work requires removing materials, the work includes disposing of the materials unlesssalvaging or incorporating the materials into the final work is described.

Wherever work includes removing, salvaging, reconstructing, abandoning, destroying, modifying,resetting, relocating, or relaying, do not start such activities until the facility is no longer needed or notbeing used.

Portions of the existing facilities that are to remain in place must be protected, preserved, and maintained.If you damage a portion of the facility that is to remain in place, you must repair or replace the damagedfacility. After the repair or replacement, the condition of the facility must be equal or better in quality than itwas before beginning the work. Remove materials that are not repaired.

Drainage facilities include culverts, inlets, headwalls, endwalls, aprons, drains, pipes, catch basins,gutters, gutter depressions, junction structures, spillways, and check dams.

15-1.02 MATERIALSNot Used

15-1.03 CONSTRUCTION15-1.03A GeneralTrenches, holes, depressions, and pits caused by removing, salvaging, reconstructing, abandoning,destroying, modifying, resetting, relocating, adjusting, relaying, remodeling, and rehabilitating highwayfacilities must be backfilled with embankment material under section 19. If the trenches, holes,


REVISION 0


depressions, and pits are in surfaced areas that otherwise remain undisturbed, backfill with material thatis equal or better in quality and to the thickness of the surrounding materials.

Where partial removal of reinforced concrete is required, remove a sufficient volume of concrete toexpose the reinforcement for splicing. Splicing must comply with section 52. Clean off material adheringto the reinforcement before placing new concrete.

15-2 MISCELLANEOUS FACILITIESNot Used

15-3 CONCRETE REMOVALNot Used

15-4 BRIDGE REMOVAL15-4.01 GENERAL15-4.01A General15-4.01A(1) SummaryFor bridge removal see Section 2050-DB Demolition.

DIVISION III GRADING16 CLEARING AND GRUBBING

Not Used

17 WATERING17-1 GENERAL

17-1.01 GENERAL17-1.01A GeneralSection 17-1 includes general specifications for watering.

If water becomes unavailable in the quantities needed for the work, the unavailability of water is amaterial shortage.

17-1.01B SubmittalsFor recycled water, submit a copy of the waste water discharge permit or waiver from the appropriateRWQCB for each water source before using the water in the work.

17-1.01C Quality Control and AssuranceFor recycled water, meet the CDPH and the appropriate RWQCB requirements. File a report with theappropriate RWQCB.

17-1.02 MATERIALSWater may be potable or nonpotable. Nonpotable water must be either recycled water or nonpotablewater developed from other sources.

17-1.03 CONSTRUCTIONNot Used

17-2 DEVELOP WATER SUPPLYNot Used

17-3 APPLY WATER17-3.01 GENERALSection 17-3 includes specifications for applying water.


REVISION 0



17-3.03 CONSTRUCTIONApply water in the quantity, at the location, and for the purpose described or ordered.

For compacting embankment material, subbase, base, and surfacing material and for dust control, applywater with the appropriate equipment to ensure the uniform application of water.

You may use a chemical additive in water for compaction if authorized.

Unless all water is applied by means of pipelines or unless otherwise authorized, you must have at least 1mobile unit available at all times. The unit must have a capacity of at least 1,000 gal.

18 DUST PALLIATIVENot Used

19 EARTHWORK19-1 GENERAL

19-1.01 GENERAL19-1.01A SummarySection 19-1 includes general specifications for performing earthwork activities including:

1. Excavating2. Excavating and replacing unsuitable material3. Removing slides and slipouts4. Preparing basement material5. Constructing embankments and shoulder backing6. Backfilling7. Grading

19-1.01B Definitionsfinished grade: Final surface of the completed facility. If the Contract includes stage construction, the

relation between finished grade and the work under this Contract is shown.

unsuitable material: Material encountered below the natural ground surface in embankment areas orbelow the grading plane in excavation areas determined to be any of the following:

1. Of such unstable nature that it cannot be compacted to the specified density using ordinary methodsat optimum moisture content.

2. Too wet to be properly compacted and cannot be dried before incorporating into the work. Excessivemoisture alone is not sufficient cause for determining that the material is unsuitable.

3. Inappropriate for planned use.


19-1.03 CONSTRUCTION19-1.03A GeneralUse material resulting from any excavation to construct embankments and dikes or you may use it tobackfill structures. If the quantity of excavated material is not sufficient to construct embankments, obtainmaterial under section 19-7.

Apply water under section 17-3.

19-1.03B Unsuitable MaterialExcavate unsuitable material.


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Notify the Engineer before removing the unsuitable material if:

1. Removal is not otherwise described

Backfill the space resulting from excavating unsuitable material with material suitable for the planned use.Place and compact suitable material under section 19-6.

19-1.03C Grade ToleranceImmediately before placing subsequent layers of material, prepare the grading plane to comply with thefollowing:

1. Where HMA is to be placed, the grading plane must not vary more than 0.05 foot above or below thegrade established by the Engineer.

2. Where PCC base or pavement is to be placed, the grading plane must not extend above the gradeestablished by the Engineer.

3. Where structure approach slabs or the thickened portion of sleeper slabs are to be placed, thegrading plane for the embankments beneath must not extend above the grade established by theEngineer.

19-1.03D Buried Man-Made ObjectsRemove and dispose of a buried man-made object encountered in an excavation as part of theexcavation work.

Notify the Engineer before removing the buried man-made object if:

1. Removal of the object is not otherwise described2. Object could not have been determined by visual inspection

19-1.03E Ditch ExcavationExcavate ditches including channels for changing the course of streams.

The excavation required to construct a ditch or channel with a bottom width less than 12 feet is classifiedas ditch excavation.

The excavation required to construct a ditch or channel with a bottom width 12 feet or more is classifiedas roadway excavation.

Avoid excavating below the grade for the bottom of the ditch or water channel. If you excavate belowgrade, backfill with suitable material and compact.

19-1.03F TestingPerform material and compaction testing in accordance with Section 2200-DB Earthwork.

19-2 ROADWAY EXCAVATIONNot Used

19-3 STRUCTURE EXCAVATION AND BACKFILL19-3.01 GENERAL19-3.01A General19-3.01A(1) SummarySection 19-3 includes specifications for performing structure excavation and backfill.

19-3.02 MATERIALS19-3.02A GeneralNot Used


REVISION 0


19-3.02B Structure BackfillStructure backfill must be free of organic or other unsatisfactory material.

Structure backfill compacted to a relative compaction of at least 95 percent and material placed behindretaining walls must have a sand equivalent value of at least 20 and comply with the gradingrequirements shown in the following table:

Sieve size Percentage passing3" 100

No. 4 35–100No. 30 20–100

Except for material placed behind retaining walls, structure backfill compacted to a relative compaction ofat least 90 percent must comply with the grading requirements shown in the following table:

Sieve size Percentage passing3" 100

Structure backfill for crib walls must comply with the requirements shown in the following tables:

Wall height(feet)

Type of backfillmaterial

Thickness of each layer ofmaterial before compaction (feet)

Under 10 C, D, or E 110–25 D or E 2

Over 25 E 4

Backfill Gradingmaterial

typeSievesize

Percentagepassing

Sandequivalent

Relativecompaction

C 3" 100 None 90% minD 3" 100 30 min 90% min

No. 4 35–100E 3" 100 None 90% min

No. 4 25–70No. 50 5–20No. 200 0–5

19-3.02C Pervious Backfill MaterialPervious backfill material must consist of one or any combination of the following materials:

1. Gravel2. Crushed gravel3. Crushed rock4. Natural sand5. Manufactured sand

Pervious backfill material must comply with the grading requirements shown in the following table:


REVISION 0


Sieve sizes Percentage passing2" 100

No. 50 0–100No. 100 0–8No. 200 0–4

Grading for sacked pervious backfill material behind wall drain outlets must comply with the gradingspecified for 1-1/2 x 3/4 inch primary aggregate in section 90-1.02C(4)(b).

19-3.02D Slurry Cement BackfillSlurry cement backfill must be a fluid workable mixture of aggregate, cement, and water.

Cement must comply with section 90-1.02B(2) except testing is not required.

Water must be free from oil, salts, and other impurities that adversely affect the backfill.

Aggregate must be one of the following:

1. Commercial-quality concrete sand2. Excavated or imported material in any combination, free of organic material and other deleterious

substances and complying with the grading requirements shown in the following table:

Sieve size Percentage passing1-1/2" 100

1" 80–1003/4" 60–1003/8" 50–100

No. 4 40–80No. 100 10–40

Proportion slurry cement backfill by weight or volume. Use at least 188 pounds of cement per cubic yard.Use sufficient water to produce a fluid workable mix that flows and can be pumped without segregationduring placement.

Mix materials thoroughly by machine. Use a pugmill, rotary drum, or other authorized mixer. Mix untilcement and water are thoroughly dispersed.

You may use slurry cement backfill as structure backfill for pipe culverts.

19-3.02E Culvert Beddings19-3.02E(1) GeneralCulvert beddings consist of shaped bedding, sand bedding, or soil cement bedding.

If more than one type of bedding is allowed, use the same bedding for the entire length of the culvert.

19-3.02E(2) Sand BeddingsSand bedding must consist of sand:

1. Free from clay or organic material2. Suitable for the purpose intended3. Complying with the grading requirements shown in the following table:

Sieve sizes Percentage passingNo. 4 90–100

No. 200 0–5


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19-3.02E(3) Soil Cement BeddingsMaterial and mixing requirements for soil cement bedding must comply with the specifications for slurrycement backfill in section 19-3.02D except:

1. Use at least 282 pounds of cement per cubic yard2. Do not use commercial-quality concrete sand as aggregate

19-3.02F Controlled Low-Strength MaterialYou may request to use controlled low-strength material as structure backfill for pipe culverts except whenpipe culverts have a diameter or span more than 20 feet.

Controlled low-strength material must be a fluid workable mixture of aggregate, cement, and water.

Cement must comply with one of the following:

1. ASTM C 1502. Blended hydraulic cement complying with either of the following:

2.1 ASTM C 5952.2 Physical requirements in ASTM C 1157

If you propose using controlled low-strength material, submit a mix design including test data beforeexcavating the trench where controlled low-strength material is to be used. When tested under ASTM D4832, the material must have a 28-day compressive strength:

1. From 50 to 100 psi for pipe culverts with 20 feet or less in height of cover2. At least 100 psi for pipe culverts with over 20 feet in height of cover

Water must be free from oil, salts, and other impurities that adversely affect the backfill.

Aggregate must be one of the following:

1. Commercial-quality concrete sand2. Excavated or imported material in any combination, free of organic material and other deleterious

substances and complying with the grading requirements shown in the following table:

Sieve size Percentage passing1-1/2" 100

1" 80–1003/4" 60–1003/8" 50–100

No. 4 40–80No. 100 10–40

19-3.02G Concrete BackfillConcrete backfill encasing steel soldier piles below the lagging must comply with section 90 and containat least 505 pounds of cementitious material per cubic yard.

19-3.02H Lean Concrete BackfillLean concrete backfill must comply with the specifications for slurry cement backfill in section 19-3.02Dexcept aggregate must be commercial-quality concrete sand.

19-3.03 CONSTRUCTION19-3.03A GeneralReserved


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19-3.03B Structure Excavation19-3.03B(1) GeneralStructure excavation includes:

1. Excavating foundations for structures, including trenches for culverts, pipes, rods, deadmen, cutoffwalls, and other facilities

2. Control and removal of water3. Installation and removal of facilities required to complete the work unless specified or allowed to

remain in place

Structure excavation (Type A) includes excavation for footings where seal courses are shown.

Obtain the Engineer's acceptance of the completed structure excavation before placing any concrete ormasonry.

When embankments must be constructed before culverts are placed, construct embankments to thespecified height and for a distance on each side of the culvert location 5 times the culvert diameter orheight before excavating for and installing culverts. Where embankments are constructed on a steepslope or at a difficult location, the Engineer may modify embankment heights before culverts are installed.

19-3.03B(2) Soldier Pile WallsNot Used

19-3.03B(3) Pier Column ExcavationNot Used

19-3.03C CofferdamsNot Used

19-3.03D Water Control and Foundation TreatmentSelect the method to remove and control water at excavations where seal courses are not shown.Methods may include well point systems, pumping sumps, cofferdams, or concrete seal courses. If youchoose a seal course, (1) the 3rd paragraph of section 51-1.03D(3), does not apply for spread footingsand (2) section 51-1.03D(3) does not apply for pile footings.

Where concrete seal courses are shown, use a cofferdam, concrete seal course, and dewatering pumps.Place seal course concrete under section 51-1.03D(3).

If no piles are used and footing concrete, culverts, or other structures are placed on an excavated surfaceother than rock, comply with the following:

1. Perform excavation without disturbing foundation material. Dewater the excavation if ground water isencountered and no seal course is used. Continue dewatering activities before or during subsequentexcavation. Foundations must be free of water when footing concrete or pipes are placed. Continuedewatering activities as required to prevent damage to the work.

2. If foundation material is disturbed by excavation activities, damaged by water, or removed for yourconvenience in dewatering, restore the foundation to a condition at least equal to the undisturbedfoundation. For culverts, use Class 2 aggregate base that complies with section 26 to replacedamaged or removed foundation material. Compact Class 2 aggregate base as specified for structurebackfill in section 19-3.03E.

If the Engineer determines the undisturbed original material of the excavation is unsuitable, correct asordered.

When footing concrete or masonry is placed on rock, the rock must be fully uncovered and the surfaceremoved to sound rock. Rock must be leveled or cut to steps and then roughened.

Pressure grout or treat seams in rock as ordered.


REVISION 0


Except for arch culverts, if you encounter solid rock or other unyielding material when excavating for aculvert at the elevation of the culvert bottom, remove the material below the bottom of the culvert to adepth of 1/24 the height of embankment above the top of culvert. This removal must be a minimum of 1foot to a maximum of 5 feet. Backfill the resulting space below the culvert using structure backfill undersection 19-3.03E.

For footings on piles, complete excavation to the bottom of footings before driving or drilling piling. If swellor subsidence results from pile driving, excavate or backfill the footing area to the grade of the bottom ofthe footing. If the material under footings would mix with footing concrete or would not support the weightof wet concrete, replace the material with suitable material, install soffit forms, or provide a platform usingauthorized means on which to cast the footing.

19-3.03E Structure Backfill19-3.03E(1) GeneralPlace structure backfill in uniform layers. Bring backfill up uniformly on all sides of structures. Backfilllayers must be at most 0.67 foot thick before compacting except when compaction is done by pondingand jetting, the thickness must be at most 4 feet.

Do not use compaction equipment or methods that may cause excessive displacement or damagestructures.

Do not place structure backfill until footings or other portions of the structure or facility are inspected bythe Engineer and authorized for backfilling. Do not place backfill against the back of abutments, retainingwalls, or outside walls of CIP concrete structures until concrete has attained a compressive strength of atleast 2,500 psi or the concrete has been in place for 28 days.

Place backfill inside bridge wingwalls and abutments before railings on wingwalls are constructed.

Compaction by ponding and jetting may be authorized under the following conditions:

1. Backfill material is self-draining when compacted2. Foundation materials will not soften or be damaged by water3. Structures will not be damaged by hydrostatic pressure

Ponding and jetting of the upper 4 feet below finished grade is not allowed. Perform work withoutdamaging the structure or embankment and such that water is not impounded. Supplement ponding andjetting with vibratory or other compaction equipment.

Compact structure backfill to a relative compaction of at least 95 percent except you may compactstructure backfill to a relative compaction of at least 90 percent at the following locations:

1. Overside drains2. Footings for slope protection, slope paving, and aprons3. Headwalls, endwalls, and culvert wingwalls4. Retaining walls, except for portions under any surfacing5. Inlets in median areas or in traffic interchange loops6. Footings and pumping plants not beneath surfacing

Where ordered, place a compacted impervious backfill material instead of structure backfill at thefollowing locations:

1. Outer 2-foot portion of structure backfill adjacent to inlets and outlets for pipes and culverts2. Structure backfill placed within 2 feet of finished grade at abutments, abutment wingwalls, retaining

walls, and other portions of structures

For the impervious backfill material, use an authorized earthy material. The sand equivalent requirementdoes not apply.


REVISION 0


Structure backfill placed at bridge supports in waterways and water channels not beneath anyembankment, pavement, or slope protection:

1. Does not need to be compacted2. Must be soil free of organic matter, trash, or other unsatisfactory material3. Must be placed to the level of original ground or finished grade shown

If you excavate outside the excavation limits shown on the plans, material placed in those excavationareas must comply with the material and compaction requirements of the adjacent structure backfill.

You may use imported borrow as structure backfill if it complies with the specifications for structurebackfill.

Material from structure excavation not suitable for use as structure backfill may be used to replaceimported borrow or other excavated material.

Material from structure excavation not used as structure backfill must be placed in roadway embankmentsunder section 19-6 or disposed of under section 19-2.03B.

19-3.03E(2) Crib WallsNot Used

19-3.03E(3) Soldier Pile WallsNot Used

19-3.03F Slurry Cement BackfillPlace slurry cement backfill within 1 hour of mixing. Place in a uniform manner without voids orsegregation. Place in a manner that does not float or shift culverts. Remove foreign material that falls intotrenches.

Do not backfill over or place material over slurry cement backfill until 4 hours after placement. Whenconcrete sand is used as aggregate and the in-place material is free draining, you may start backfilling assoon as the surface water is gone.

If slurry cement backfill is used for structure backfill, you may reduce the excavation width so that theclear distance between the outside of the pipe and the side of the excavation on each side of the pipe isat least (1) 6 inches for pipes 42 inches or less in diameter or span or (2) 1 foot for pipes over 42 inchesin diameter or span.

Place slurry cement backfill only for that portion of structure backfill (1) below the original ground orgrading plane or (2) below the top of embankment placed before excavating for culvert pipe. Wherenecessary, compact earth plugs at each end of the pipe before placing backfill to completely containslurry in the pipe trench.

19-3.03G Pervious Backfill MaterialPlace pervious backfill material in layers along with and by the same methods specified for structurebackfill. Pervious backfill material at any one location must have approximately the same grading. Coverpervious backfill material at locations exposed to erosion with a 1-foot layer of authorized earthenmaterial.

19-4 NOT USED19-5 COMPACTION

19-5.01 GENERAL19-5.01A SummarySection 19-5 includes specifications for obtaining required compaction for all earthwork except structurebackfill.


REVISION 0



19-5.03 CONSTRUCTION19-5.03A GeneralRelative compaction specifications apply to material whether in excavation or embankment.

The moisture content of material to be compacted to at least 95 percent must be such that the specifiedrelative compaction is obtained and the embankment is in a firm and stable condition.

Do not compact material that contains excessive moisture until the material is dry enough.

19-5.03B Relative Compaction (95 Percent)Obtain a relative compaction of at least 95 percent for at least a depth of:

1. 0.5 foot below the grading plane for the width between the outer edges of shoulders2. 2.5 feet below the finished grade for the width of the traveled way plus 3 feet on each side

Except for the outer 5 feet measured horizontally from the embankment side slope, compact the full widthand depth of the embankment within 150 feet of each bridge abutment to at least 95 percent relativecompaction. The 150-foot limit is measured horizontally from the bridge abutment and either parallel orconcentric with the roadway centerline.

Obtain a relative compaction of at least 95 percent for embankments under retaining wall footings withoutpile foundations:

1. For the full depth2. Within the limits established by inclined planes sloping 1.5:1 (horizontal:vertical) out and down from

lines 1 foot outside the bottom edges of the footing.

19-5.03C Relative Compaction (90 Percent)Obtain a relative compaction of at least 90 percent in embankment areas not required to be compacted to95 percent.

19-5.03D Foundation PreparationYou are responsible for preparing the foundation to receive material.

If you elect to excavate and replace basement material to facilitate compaction, before replacementbegins and if ordered, compact a layer below the excavated material to the depth, width, and degree ofcompaction ordered.

19-6 EMBANKMENT CONSTRUCTION19-6.01 GENERAL19-6.01A SummarySection 19-6 includes specifications for constructing embankments.

Embankment construction includes:

1. Preparing areas to receive embankment material2. Placing and compacting embankment material including:

2.1. Suitable material within roadway areas where unsuitable material has been removed2.2. Material in holes, pits, and other depressions within the roadway area

3. Constructing a temporary surcharge embankment above the grading plane4. Constructing dikes on or off the job site

19-6.01B SubmittalsSubmit a Settlement Monitoring plan for approval by the Engineer of Record.


REVISION 0


19-6.02 MATERIALS19-6.02A GeneralUse material from excavations or from local or imported borrow.

In embankment areas where piles are to be placed or driven, do not use material containing rocks,broken concrete, or other solid materials larger than 4 inches in greatest dimension.

Whenever selection of material is possible, do not place borrow or excavation material having a sandequivalent value less than 10 within 2.5 feet of finished grade. Use this material to construct the lowerportions of embankments.

19-6.02B Geosynthetic Reinforced EmbankmentEach geosynthetic reinforcement roll must be labeled with:

1. Manufacturer's name2. Production identification3. Roll dimensions4. Lot number5. Date of manufacture

Backfill for geosynthetic reinforced embankment must be free from:

1. Organic material2. Shale, soft, or poor durability particles3. Recycled materials such as glass, shredded tires, concrete rubble, or other unsuitable materials4. Loose or extraneous material and sharp objects that may come in contact with the geosynthetic

reinforcement

Backfill must comply with the requirements in the following 2 tables:

Sieve size Percent passing1-1/2" 1003/4" 75–100

No. 4 20–100No. 40 0–60No. 200 0–50

Property Requirement California TestPlasticity index 20 max 204

pH 5–9 643

The Engineer may authorize the use of backfill with grading larger than the specified size up to a 4 inchesmaximum if you submit, with your LTDS calculations, test results for installation damage reduction factorsfor each type of geosynthetic reinforcement under FHWA-NHI-00-044, section 5.1.

19-6.03 CONSTRUCTION19-6.03A GeneralCompact embankment under section 19-5.

Construct embankment slopes under section 19-2.03G.

When constructing an embankment on an existing roadway, scarify, water, grade, and roll the existingroadbed before placing new material.


REVISION 0


When constructing an embankment against an existing slope or when constructing 1/2 the embankmentwidth at a time, prepare the slope by cutting into it at least 6 feet horizontally as you place the newembankment in layers. Compact the cut material along with the new embankment material.

For bridge footings to be constructed in embankment, construct the embankment to the grading planeelevation and extend the finished slope to the grading plane before:

1. Excavating for footings2. Driving piles or drilling holes for CIP piles

The grading plane of embankments beneath structure approach slabs and beneath the thickened portionof sleeper slabs must not project above the grade established by the Engineer.

Grade trenches, holes, depressions, and pits outside of areas where embankments are to be constructedto provide a presentable and well-drained area.

19-6.03B SubsidenceNot Used

19-6.03C Placing and CompactingDo not construct embankments when material is frozen or a blanket of snow prevents proper compaction.

Construct embankment in layers. The loose thickness of each layer must not exceed 8 inches.

Break up clods or hard lumps of earth that are over 8 inches in greatest dimension before compactingmaterial in the embankment, except if material, such as hardpan or cemented gravel, cannot be brokenreadily:

1. Distribute material throughout the embankment2. Place enough earth or other fine material around the larger material as you deposit it to fill the

interstices and produce a dense, compact embankment.

If embankment material contains the following percentages by volume of rock larger than 8 inches ingreatest dimension, before compaction, the loose thickness of each layer of embankment material belowa plane 3 feet below finished grade must comply with the following table:

Percent by volume Loose layer thicknessOver 50 Max. rock sizeFrom 25 to 50 Max. rock size up to 3 feetLess than 25 8 inches in areas between rocks

larger than 8 inches

Reinforcement or metal attached to reinforced concrete rubble placed in embankments must not protrudeabove the grading plane. Trim reinforcement or metal to less than 3/4 inch from the face of the reinforcedconcrete rubble material before placing the material within 2 feet below the grading plane.

In a sidehill embankment where the width, including bench cuts for bonding existing and newembankments, is too narrow to accommodate mobile power compacting equipment, you may place thematerial by end dumping, if authorized.

If end dumping is allowed for constructing embankment against existing slopes or 1/2 the embankmentwidth at a time, then plow or cut the slopes of the original ground or embankment before end dumpingstarts.

Where embankments are constructed across low, swampy ground that cannot support the weight ofhauling equipment, you may construct the lower part of the embankment by dumping successive loads ina uniformly distributed layer that can support equipment for placing subsequent layers.

Construct embankments such that each layer has a cross fall less than 5 percent.


REVISION 0


At locations where it is impractical to use mobile power compacting equipment, compact embankmentlayers by any method that obtains the specified compaction.

19-6.03D Settlement Periods and SurchargesWhere an embankment settlement period is specified, construct the embankment to the elevations andlimits specified by the Geotechnical Engineer and as approved in the Settlement Monitoring plan.

Retain embankment and any specified surcharge from encroaching upon the traveled way or existingimprovements.

The settlement period starts after the embankment construction begins.

Install settlement platforms per approved Settlement Monitoring plan.

Settlement is deemed complete if less than 0.1 inches of settlement is measured over a period of twoweeks after completion of the embankment.19-6.03E Geosynthetic Reinforced EmbankmentPlace geosynthetic reinforcement within 3 inches of the design elevations.

Place at least 3 inches of compacted backfill between layers of geosynthetic reinforcement, unlessotherwise shown.

Geosynthetic reinforcement must be:

1. Secured with staples, pins, or small piles of backfill2. Placed without wrinkles3. Aligned with the primary strength direction perpendicular to slope contours4. Spliced under manufacturer's instructions5. Butted edge-to-edge for straight slope contours6. Butted edge-to-edge at the slope face and fanned out or overlapped into the backfill for curved slope

contours

Cover geosynthetic reinforcement with backfill within the same work shift.

Place at least 6 inches of backfill on the geosynthetic reinforcement before operating or driving equipmentor vehicles over it, except those used under the conditions specified below for spreading backfill.

You may drive equipment or vehicles for spreading backfill directly on the geosynthetic reinforcement ifyou:

1. Comply with manufacturer's instructions2. Use rubber-tire vehicles3. Minimize traffic repetitions4. Maintain speed less than 5 mph5. Avoid sudden braking and sharp turning

Where guard railing posts will be placed at the top crest of the geosynthetic reinforced embankment andthe geosynthetic reinforcement interferes with placement of posts, you may precut affected layers ofreinforcement into cross-shaped patterns. The precutting dimensions must not exceed post dimensionsby more than 12 inches.

Do not extend geosynthetic reinforcement into the pavement structure.

Replace or repair any geogrid reinforcement damaged during construction. Repair by placing additionalreinforcement to cover the damaged area and:

1. For reinforcement placed parallel to slope contours, overlapping 5 aperture openings or 8 incheswhichever is greater

2. For reinforcement placed perpendicular to slope contours, splicing the edges as instructed by themanufacturer


REVISION 0


Replace any geotextile reinforcement damaged during construction.

Grade and compact backfill to ensure the reinforcement remains taut.

Compact backfill under section 19-5.03C. If hand-operated equipment is used, do not place more than 6inches of backfill before compaction.

Use hand-operated equipment to compact areas within 3 feet of:

1. Slope contours2. Underground structures

Do not disk or plow in the reinforced area.

20 LANDSCAPENot Used

21 EROSION CONTROLNot Used

22 FINISHING ROADWAYNot Used

23 NOT USEDNot Used

DIVISION IV SUBBASES AND BASES24 STABILIZED SOILS

Not Used

25 AGGREGATE SUBBASESNot Used

26 AGGREGATE BASES26-1.01 GENERALSection 26 includes specifications for spreading and compacting AB.

26-1.02 MATERIALS26-1.02A GeneralAggregate for Class 2 and Class 3 AB must be clean and consist of any combination of the following:

1. Broken stone2. Crushed gravel3. Natural rough surfaced gravel4. Sand5. Processed reclaimed asphalt concrete, PCC, LCB, or CTB

Use either 1-1/2 inch or 3/4 inch aggregate grading. Do not change your selected aggregate gradingwithout authorization.

If the aggregate grading test results, sand equivalent test results, or both comply with contract compliancerequirements but not operating range requirements, you may continue placing AB for the remainder of the


REVISION 0


work day. Do not place additional AB until you demonstrate to the Engineer the AB to be placed complieswith the operating range requirements.

If the aggregate grading test results, sand equivalent test results, or both do not comply with contractcompliance requirements, remove the AB.

26-1.02B Class 2 Aggregate BaseWhen tested under California Test 202, aggregate must comply with the grading requirements for thesieve sizes shown in the following table:

Aggregate Grading

Sieve sizes

Percentage passing1-1/2 inch maximum 3/4 inch maximum

Operatingrange

Contractcompliance

Operatingrange

Contractcompliance

2" 100 100 -- --1-1/2" 90-100 87-100 -- --1" -- -- 100 1003/4" 50-85 45-90 90-100 87-100No. 4 25-45 20-50 35-60 30-65No. 30 10-25 6-29 10-30 5-35No. 200 2-9 0-12 2-9 0-12

Aggregate must comply with the quality requirements shown in the following table:

Aggregate QualityProperty California

TestOperating range Contract compliance

Resistance (R-value) (min) 301 -- 78Sand equivalent (min) 217 25 22Durability index (min) 229 -- 35

Aggregate samples must not be treated with lime, cement, or chemicals before testing for durability index.Aggregate from untreated reclaimed processed asphalt concrete, PCC, LCB, or CTB is not consideredtreated.

26-1.02C Class 3 Aggregate BaseWhen tested under California Test 202, aggregate must comply with the grading requirements for thesieve sizes shown in the following table:

Aggregate Grading

Sievesizes

Percentage passing1-1/2 inch maximum 3/4 inch maximum

Operatingrange Contract compliance Operating range Contract

compliance2" 100 100 -- --1-1/2" 90-100 87-100 -- --1" -- -- 100 1003/4" 50-90 45-95 90-100 87-100No. 4 25-60 20-65 40-70 35-75No. 30 10-35 6-39 12-40 7-45No. 200 3-15 0-19 3-15 0-19


REVISION 0


Aggregate must comply with the quality requirements shown in the following table:

Aggregate QualityProperty California

TestOperating range Contract compliance

Resistance (R-value) (min) 301 -- 50Sand equivalent (min) 217 21 18

26-1.03 CONSTRUCTION26-1.03A GeneralWater AB under section 17-3.

26-1.03B SubgradeImmediately before spreading AB, the subgrade must comply with the specified compaction and elevationtolerance for the material involved and be free from loose or extraneous material.

Fill areas of finished AS that are lower than the grade established by the Engineer with AB.

26-1.03C SpreadingDeliver uniform mixtures of AB to the roadbed. Deposit AB in layers or windrows. Spread and shape theAB to such thickness that after watering and compacting, the completed AB is within the tolerancesspecified in section 26-1.03D. When AB is spread and compacted the moisture content must be uniformand sufficient to obtain the required compaction. Avoid material segregation. AB must be free frompockets of coarse or fine material.

Where the subgrade is cohesionless sand you may dump AB in piles and spread it ahead in sufficientquantities to stabilize the subgrade, if authorized.

Where the shown AB thickness is 0.50 foot or less you may spread and compact the AB in one layer.Where the shown thickness is more than 0.50 foot, spread and compact in 2 or more layersapproximately equal in thickness. The compacted thickness of any one layer must not exceed 0.50 foot.At locations inaccessible to spreading equipment, spread and compact AB by any means that will obtainthe specified results.

26-1.03D CompactingCompact each AB layer to at least 95 percent relative compaction under California Test 231.

The finished AB surface must not vary more than 0.05 foot from the grade established by the Engineer.

Correct areas of AB that do not comply with the described thickness.

27 CEMENT TREATED BASESNot Used

28 CONCRETE BASESNot Used

29 TREATED PERMEABLE BASES29-1.01 GENERALSection 29 includes specifications for mixing aggregate with asphalt binder or mixing aggregate withportland cement and water, spreading, compacting, and shaping the mixture.



REVISION 0


29-1.02B Asphalt Treated Permeable BaseNot Used

29-1.02C Cement Treated Permeable BaseAggregate must comply with section 90-1.02C. Aggregate grading must comply with the specifications forthe 1" x no. 4 primary aggregate nominal size coarse grading in section 90-1.02C(4)(b).

Cement must comply with section 90-1.02B(2),Type II.

Water must comply with section 90-1.02D.

29-1.03 CONSTRUCTION29-1.03A GeneralImmediately before spreading treated permeable base, the subgrade must:

1. Comply with the specified compaction and elevation tolerance for the material involved2. Be free from loose or extraneous material3. Be uniformly moist

Areas of subgrade lower than the grade established by the Engineer must be filled with treatedpermeable base.

Spread treated permeable base when the atmospheric temperature is above 40 degrees F.

Finish treated permeable base to a uniform surface within 0.05 foot of the grade established by theEngineer.

Place filter fabric on the edge and on the top of the high side (the side opposite the edge drain side) of thetreated permeable base and at intermediate cross drain interceptors. Place filter fabric under section 68-1.03.

Place and compact treated permeable base for edge drains under section 68-4.02C.

29-1.03B Asphalt Treated Permeable BaseNot Used

29-1.03C Cement Treated Permeable BaseStore, proportion, mix, and transport aggregates, cement and water, under sections 90-1.02F and 90-1.02G except, aggregate does not have to be separated into sizes and the water amount and penetrationrequirements do not apply.

The cement content of CTPB must be at least 287 lb/cu yd.

The water to cement ratio must be approximately 0.37. The Engineer determines the exact water tocement ratio.

Place CTPB under section 40-1.03H(1) except the 3rd paragraph does not apply.

Spread, compact, and shape CTPB under section 40-1.03H(4) or under section 40-1.03H(5). Vibratorsmust not be used.

Compact with a 2-axle steel-tired roller weighing from 6 to 10 tons. Compact within 30 minutes afterspreading the base. Compaction must consist of 2 complete passes of the CTPB.

Cure CTPB by sprinkling the completed surface with a fine spray of water every 2 hours for a period of 8hours. Start curing the morning after base has been placed.

29-1.03D Surfaces Out of ToleranceWhere the surface of treated permeable base is higher than 0.05 foot from the grade established by theEngineer, remove the base and replace it with the specified treated permeable base. If authorized,


REVISION 0


remove high spots to comply with the specified tolerance by any method that does not producecontaminating fines or damage the base remaining in place. Grinding is not allowed.

Where the surface of treated permeable base is lower than 0.05 foot from the grade established by theEngineer, remove the base and replace it with the specified treated permeable base. If authorized, fill lowareas with pavement material as follows:

1. For HMA pavement, fill low areas with HMA that complies with the specifications for the lowest layerof HMA pavement. Do not fill low areas concurrently with the HMA paving operation.

2. For concrete pavement, fill low areas with paving concrete concurrent with the concrete pavementpaving operation.

30-36 NOT USED

DIVISION V SURFACING AND PAVEMENTS37 BITUMINOUS SEALS

Not Used

38 NOT USED

39 HOT MIX ASPHALTNot Used

40 CONCRETE PAVEMENT40-1 GENERAL

40-1.01 GENERALNot Used


40-1.03 CONSTRUCTION40-1.03A GeneralAggregate and bulk cementitious material must be proportioned by weight by means of automaticproportioning devices of approved types.

40-1.03B Water SupplyBefore placing concrete pavement, develop enough water supply for the work.

40-1.03C Subgrade PreparationImmediately before placing concrete, the subgrade to receive concrete must be:

1. In compliance with the specified compaction and elevation tolerances2. Free of loose and extraneous material3. Uniformly moist, but free of standing or flowing water4. Excavated for thickened parts of concrete pavement end anchors with no disturbed compaction

outside the end anchor dimensions

For cement treated permeable base, cover the base surface with asphaltic emulsion before placingconcrete pavement. Apply the asphaltic emulsion uniformly at a rate of 0.1 gal/sq yd. Asphaltic emulsionmust comply with anionic slow-setting type, SS1h grade in section 94 of the Standard Specifications.Repair damaged asphaltic emulsion before placing concrete pavement.


REVISION 0


40-1.03D Shoulder Rumble Strip40-1.03D(1) GeneralConstruct shoulder rumble strips by rolling or grinding indentations in new concrete pavement.

Do not construct shoulder rumble strips on structures or approach slabs.

Construct rumble strips within 2 inches of the specified alignment. Rumble strip equipment must beequipped with a sighting device enabling the operator to maintain the rumble strip alignment.

Indentations must not vary from the specified dimensions by more than 1/16 inch in depth or more than10 percent in length and width.

Grind or remove and replace noncompliant rumble strip indentations as determined by the Engineer tobring them to within specified tolerances. Ground surface areas must be neat and uniform in appearance.

Pick up residue from grinding with a vacuum attachment on the grinding machine.

40-1.03D(2) Ground-In IndentationsConcrete pavement must be hardened before grinding rumble strips indentations. Do not constructindentations until the following occurs:

1. 10 days elapse after concrete placement2. Concrete has developed a modulus of rupture of 550 psi determined under California Test 523,

40-1.03D(3) Rolled-In IndentationsConstruct rolled-in indentations before final concrete set. Indentation construction must not displaceadjacent concrete.

40-1.03E Joints40-1.03E(1) GeneralConcrete pavement joints consist of:

1. Longitudinal and transverse construction joints2. Longitudinal and transverse contraction joints3. Isolation joints

Construction joints must be perpendicular to the concrete pavement surface.

Keep joints free from foreign material including soil, gravel, concrete, or asphalt mix until Contractacceptance.

For concrete pavement damaged during joint construction, repair the pavement under section 40-1.03Q(2).

Do not bend tie bars or reinforcement in existing concrete pavement joints.

40-1.03E(2) Construction JointsConstruction joints form where fresh concrete is placed against hardened concrete, existing pavements,or structures.

Before placing concrete at construction joints, apply curing compound no. 1 or 2 to the vertical surface ofexisting or hardened concrete and allow it to dry.

Use a metal or wooden bulkhead to form transverse construction joints. If dowel bars are specified, thebulkhead must allow dowel bar installation.

If a transition joint between concrete pavement and HMA is specified, apply tack coat between theconcrete pavement and HMA.


REVISION 0


40-1.03E(3) Contraction JointsIn monolithic concrete pavement, construct longitudinal contraction joints as shown with the sawingmethod. Construct transverse contraction joints with the sawing method.

Construct transverse contraction joints within 1 foot of their specified spacing. If a slab length of less than5 feet would be formed, adjust the transverse contraction joint spacing.

Construct transverse contraction joints across the full concrete pavement width regardless of the numberor types of longitudinal joints crossed. In areas of converging and diverging pavements, space transversecontraction joints so their alignment is continuous across the full width where converging and divergingpavements are contiguous. Longitudinal contraction joints must be parallel with the concrete pavementcenterline. Transverse and longitudinal contraction joints must not deviate by more than 0.1 foot fromeither side of a 12-foot straight line, except for longitudinal joints parallel to a curving centerline.

If widening existing concrete pavement, do not construct transverse contraction joints to match theexisting pavement's joint spacing or skew unless specified.

40-1.03E(4) Isolation JointsConstruct isolation joints by saw cutting a minimum 1/8-inch width to full concrete pavement depth at theexisting concrete pavement's edge. Remove the concrete to expose a flat vertical surface. Before placingconcrete, secure joint filler material that prevents new concrete from adhering to the existing concreteface.

40-1.03E(5) Sawing MethodSawing method consists of cutting a groove in the concrete pavement with a power driven concrete saw.Grooves for longitudinal and transverse contraction joints must be the minimum width possible for thetype of saw used. If necessary, the top of the joint must be sawn wider to provide space for joint sealant.Immediately wash slurry from the joint with water at 100 psi maximum pressure.

Saw longitudinal and transverse contraction joints before cracking occurs and after the concrete is hardenough to saw without spalling, raveling, or tearing.

To keep foreign material out of grooves before joint sealant or compression seal installation, you may usea filler in sawed contraction joints. Joint filler material must not react adversely with the concrete or causeconcrete pavement damage. After sawing and washing a joint, install joint filler material that keepsmoisture in the adjacent concrete during the 72 hours after paving. If you install joint filler material, thespecifications for spraying the sawed joint with additional curing compound in section 40-1.03N do notapply. If using absorptive filler material, moisten the filler immediately before or after installation.

40-1.03E(6) Joint Sealant and Compression Seal Installation40-1.03E(6)(a) GeneralDo not seal construction joints.

At least 7 days after concrete pavement placement and not more than 4 hours before installing jointsealant or compression seal materials, use dry sandblasting and other methods to clean the joint walls ofobjectionable material such as soil, asphalt, curing compound, paint, and rust. The maximumsandblasting nozzle diameter must be 1/4 inch. The minimum pressure must be 90 psi. Sandblast eachside of the joint at least once, in at least 2 separate passes. Hold the nozzle at an angle to the joint from 1to 2 inches from the concrete pavement. Using a vacuum, collect sand, dust, and loose material at least 2inches on each side of the joint. Remove surface moisture and dampness at the joints with compressedair that may be moderately hot.

Before you install joint sealant or compression seal, the joint wall must be free of moisture, residue, orfilm.

If grinding or grooving over or adjacent to sealed joints, remove and dispose of joint sealant orcompression seal materials. After grinding or grooving, replace the joint sealant or compression sealmaterials.


REVISION 0


40-1.03E(6)(b) Liquid SealantInstall backer rods when the concrete pavement temperature is above the air dew point and when the airtemperature is at least 40 degrees F.

Install liquid sealant immediately after installing the backer rod. Install sealant using a mechanical devicewith a nozzle shaped to introduce the sealant from inside the joint. Extrude sealant evenly and withcontinuous contact with the joint walls. Recess the sealant surface after placement. Remove excesssealant from the concrete pavement surface.

Do not allow traffic over sealed joints until the sealant is set.

40-1.03E(6)(c) Preformed Compression SealInstall preformed compressions seals in isolation joints when specified.

Install longitudinal seals before transverse seals. Longitudinal seals must be continuous except atintersections with transverse seals. Install transverse seals in 1 continuous piece for the entire transverselength of concrete pavement. With a sharp instrument, cut across the longitudinal seal at the intersectionwith transverse construction joints. If the longitudinal seal does not relax enough to properly install thetransverse seal, trim the longitudinal seal to form a tight seal between the 2 joints.

Use a machine specifically designed for preformed compression seal installation. The machine mustinstall the seal:

1. To the specified depth2. To make continuous contact with the joint walls3. Without cutting, nicking, or twisting the seal4. With less than 4 percent stretch

Lay a length of preformed compression seal material cut to the exact length of the pavement joint to besealed. The Engineer measures this length. After you install the length of preformed compression jointsealant, the Engineer measures the excess amount of material at the joint end. The Engineer divides theexcess amount length by the original measured length to determine the percentage of stretch.

40-1.03F Drilled CoresDrill concrete pavement cores under ASTM C 42/C 42M. Core drilling equipment must use diamondimpregnated bits.

Clean, dry, and fill core holes with hydraulic cement grout (non-shrink) or pavement concrete. Coat thecore hole walls with epoxy adhesive for bonding new concrete to old concrete under section 95. Thebackfill must match the adjacent concrete pavement surface elevation and texture.

40-1.03G Test StripsSection 40-1.03G applies to projects with more than 2,000 cubic yards of JPCP or CRCP.

The first paving activity must be to construct a test strip:

1. 700 to 1,000 feet long2. Same width as the planned paving3. With the same equipment used for the planned paving

The Engineer evaluates the test strip for compliance with the specifications for acceptance criteria.

The Engineer selects from 6 to 12 core locations for dowel bars and up to 6 locations for tie bars per teststrip.

If you use mechanical dowel bar inserters, the test strip must demonstrate they do not leave voids,segregations, or surface irregularities such as depressions, dips, or high areas.

Allow the Engineer 3 business days to evaluate the test strip for:


REVISION 0


1. Smoothness2. Dowel bar and tie bar alignment3. Thickness4. Final finishing except coefficient of friction

During the 3 business day evaluation, the Engineer rejects a test strip if any of the following occurs:

1. Surface varies more than 0.02 foot from a 12-foot straightedge's lower edge2. Wheel path's individual high points are greater than 0.025 foot in 25 feet3. Dowel bars do not comply with specified placement tolerances4. Concrete pavement thickness deficiency is greater than 0.05 foot5. Final finishing does not comply with the specifications except coefficient of friction

Remove the test strip if the Engineer rejects it for noncompliance with the specifications for dowel baralignment, or thickness. Dispose of rejected test strip material.

If the Engineer rejects the test strip for noncompliance with the smoothness or final finishingspecifications except coefficient of friction, you may grind the test strip into compliance if you intend toleave it as part of the paving.

If the Engineer does not reject the test strip during the 3-business-day evaluation, you may beginproduction paving while the Engineer continues to evaluate the test strip for compliance with the otherspecifications. If the Engineer rejects the test strip for noncompliance with the other specifications, stopproduction paving until you construct a test strip the Engineer accepts.

For rejected test strips, submit a plan for changed materials, methods, or equipment before constructingadditional test strips. Construct additional test strips until the Engineer accepts one.

Construct additional test strips if you:

1. Propose different paving equipment including:1.1. Batch plant1.2. Paver1.3. Dowel bar inserter1.4. Tie bar inserter1.5. Tining1.6. Curing equipment

2. Change concrete mix proportions

The Engineer may authorize paving to start without a test strip if you use a batch plant mixer, pavingequipment, and personnel that completed a Department project of the same type within the preceding 12months. Submit supporting documents and previous project information.

40-1.03H Placing Concrete40-1.03H(1) GeneralPlace concrete pavement with stationary side forms or slip-form paving equipment.

Place consecutive concrete loads within 30 minutes of each other. Construct a transverse constructionjoint when concrete placement is interrupted by more than 30 minutes. The transverse construction jointmust coincide with the next contraction joint location, or you must remove fresh concrete pavement to thepreceding transverse joint location.

Place concrete pavement in full slab widths separated by construction joints or monolithically in multiplesof full lane widths with a longitudinal contraction joint at each traffic lane line.

Do not retemper concrete.

If the concrete pavement surface width is constructed as specified, you may construct concrete pavementsides on a batter not flatter than 6:1 (vertical:horizontal).


REVISION 0


40-1.03H(2) Concrete Pavement WideningIf concrete pavement is placed adjacent to existing pavement not constructed as part of the contract,grind the existing concrete pavement lane or shoulder adjacent to the new concrete pavement. Performthe grinding before new concrete pavement is placed. The new concrete pavement must match theelevation of the existing concrete pavement after grinding. Grind existing concrete pavement undersection 42-3 of the Standard Specifications except profile index must comply with the pavementsmoothness specifications in section 40-1.01D of the Standard Specifications.

Use paving equipment with padded crawler tracks or rubber-tired wheels on the existing concretepavement with enough offset to avoid breaking or cracking the existing concrete pavement's edge.

40-1.03H(3) Concrete Pavement Transition PanelFor concrete pavement placed in a transition panel, texture the surface with a drag strip of burlap, abroom, or a spring steel tine device that produces scoring in the finished surface. The scoring must beeither parallel with or transverse to the centerline. For the method you choose, texture at the time thatproduces the coarsest texture.

40-1.03H(4) Stationary Side Form ConstructionStationary side forms must be straight and without defects including warps, bends, and indentations. Sideforms must be metal except at end closures and transverse construction joints where other materials maybe used.

You may build up side forms by attaching a section to the top or bottom. If attached to the top of metalforms, the attached section must be metal.

The side form's base width must be at least 80 percent of the specified concrete pavement thickness.

Side forms including interlocking connections with adjoining forms must be rigid enough to preventspringing from subgrading and paving equipment and concrete pressure.

Construct subgrade to final grade before placing side forms. Side forms must bear fully on the foundationthroughout their length and base width. Place side forms to the specified grade and alignment of thefinished concrete pavement's edge. Support side forms during concrete placing, compacting, andfinishing.

After subgrade work is complete and immediately before placing concrete, true side forms and set to lineand grade for a distance that avoids delays due to form adjustment.

Clean and oil side forms before each use.

Side forms must remain in place for at least 1 day after placing concrete and until the concrete pavementedge no longer requires protection from the forms.

Spread, screed, shape, and consolidate concrete with 1 or more machines. The machines must uniformlydistribute and consolidate the concrete. The machines must operate to place the concrete pavement tothe specified cross section with minimal hand work.

Consolidate the concrete without segregation. If vibrators are used:

1. The vibration rate must be at least 3,500 cycles per minute for surface vibrators and 5,000 cycles perminute for internal vibrators

2. Amplitude of vibration must cause perceptible concrete surface movement at least 1 foot from thevibrating element

3. Use a calibrated tachometer for measuring frequency of vibration4. Vibrators must not rest on side forms or new concrete pavement5. Power to vibrators must automatically cease when forward or backward motion of the paving machine

is stopped


REVISION 0


Use high-frequency internal vibrators within 15 minutes of depositing concrete on the subgrade touniformly consolidate the concrete across the paving width including adjacent to forms. Do not usevibrators to shift the mass of concrete.

40-1.03H(5) Slip-Form ConstructionIf slip-form construction is used, spread, screed, shape, and consolidate concrete to the specified crosssection with slip-form machines and minimal hand work. Slip-form paving machines must be equippedwith traveling side forms and must not segregate the concrete.

Do not deviate from the specified concrete pavement alignment by more than 0.1 foot.

Slip-form paving machines must use high frequency internal vibrators to consolidate concrete. You maymount vibrators with their axes parallel or normal to the concrete pavement alignment. If mounted withaxes parallel to the concrete pavement alignment, space vibrators no more than 2.5 feet measured centerto center. If mounted with axes normal to the concrete pavement alignment, space the vibrators with amaximum 0.5-foot lateral clearance between individual vibrators.

Each vibrator must have a vibration rate from 5,000 to 8,000 cycles per minute. The amplitude of vibrationmust cause perceptible concrete surface movement at least 1 foot from the vibrating element. Use acalibrated tachometer to measure frequency of vibration.

41 CONCRETE PAVEMENT REPAIRNot Used

42 GROOVE AND GRIND CONCRETENot Used

43–45 NOT USED

DIVISION VI STRUCTURES46 GROUND ANCHORS AND SOIL NAILS

46-1 GENERALNot Used

46-2 GROUND ANCHORS46-2.01 GENERALNot Used

46-2.02 MATERIALS46-2.02A GeneralIf a bond breaker is shown near the bearing plate, use a 1/4-inch premolded joint filler that complies withsection 51-2.01.

46-2.02B SteelThe anchorage enclosure and the steel tube and bearing plate of the anchorage assembly must begalvanized steel complying with section 55. Section 11-3.02 does not apply to the anchorage enclosurewelds or to the weld between the steel tube and the bearing plate.

The permanent bearing plate must effectively distribute the factored test load uniformly to the concretesuch that:

1. Concrete bearing stress does not exceed 2,400 psi2. Bending stress of the plate does not exceed:

2.1. 0.90 of the yield strength for steel


REVISION 0


2.2. 0.55 of the yield strength for cast steel or cast iron

46-2.02C Sheathing46-2.02C(1) GeneralPolypropylene sheathing must have a density of from 900 to 910 kg/m3 when measured under ASTM D792.

46-2.02C(2) Smooth Plastic SheathingSmooth sheathing for bar tendons must be PVC or HDPE.

Smooth sheathing for encapsulating individual strands of strand tendons must be HDPE or polypropyleneand must have a minimum wall thickness of 40 mils.

46-2.02C(3) Corrugated Plastic SheathingCorrugated plastic sheathing must be PVC or HDPE.

PVC corrugated sheathing must have a nominal wall thickness of 40 mils.

HDPE corrugated sheathing with an outside diameter of 3 inches or greater must have a nominal wallthickness of 60 mils. HDPE corrugated sheathing with an outside diameter of less than 3 inches musthave a nominal wall thickness of 40 mils.

46-2.02D Strand Coating and EncapsulationWithin the unbonded length of strand tendons, fully coat each individual strand with corrosion-inhibitinggrease and encapsulate it with a smooth HDPE or polypropylene sheath.

Hot melt extrude or shop apply the sheath onto the strand using a method that ensures all spacesbetween the sheath, strand, and strand wires are filled with corrosion-inhibiting grease.

The corrosion-inhibiting grease must:

1. Fill all space between the strand wires2. Encapsulate the strand, giving an encasement diameter at least 5 mils greater than the diameter of

the bare strand3. Provide a continuous, nonbrittle film of corrosion protection to the prestressing steel4. Provide lubrication between the strand and the sheathing5. Resist flow from the sheathing6. Be chemically stable and nonreactive with the prestressing steel, sheathing material, and concrete7. Be organic8. Have appropriate polar, moisture-displacing, and corrosion-inhibiting additives9. Have the physical properties shown in Table 1 of Specification for Unbonded Single Strand Tendons

published by the Post-Tensioning Institute

47 EARTH RETAINING SYSTEMS47-1 GENERAL

47-1.01 GENERALSection 47 includes specifications for constructing earth retaining systems.

47-2 MECHANICALLY STABILIZED EMBANKMENT47-2.01 General47-2.01A SummarySection 47-2 includes specifications for constructing mechanically stabilized embankments.

Concrete panels must comply with section 51.

Reinforcement must comply with section 52.


REVISION 0


Geogrid reinforcement must comply with section 88.

Earthwork must comply with section 19.

47-2.01B DefinitionsNot Used

47-2.01C SubmittalsSubmit shop drawings for the MSE walls to OSD Include the following:

1. All information required for construction of the system at each location2. Existing ground line at the wall face3. Design parameters, material notes, and wall construction procedures

Verify existing ground elevations before submitting drawings.

Shop drawings and calculations must be sealed and signed by an engineer who is registered as a CivilEngineer in the State of California. Calculations shall be checked for concurrence.

Submit results from proposed button-head wire coupler test.

Submit results from each production button-head wire coupler test.

47-2.01D Quality Control and AssurancePerform tension and slip tests on the proposed button-head wire soil reinforcement and couplerconnection. Testing must be performed by an authorized laboratory. Test 6 connection test samples. Testsamples must consist of 2 button-head wires each 24 inches long connected by a swaged coupler.Coupler connection must comply with ACI 12.14.3.2.

Coupler test samples must comply with minimum tensile specifications for steel wire in ASTM A 82/A82M. Total wire slip must be at most 3/16 inch when tested under the specifications for tension testing ofround wire test samples in ASTM A 370.

If any test samples fail, revise the connection and retest. Do not start face panel installation until tensionand slip test results are accepted.

Perform tension and slip testing on production button-head wire and coupler connections during wallconstruction. Test 4 connection test samples for each lot of 500 mat wire connections used in the work. If2 or more test samples fail, the entire represented lot is rejected. If 1 test sample fails to comply withspecified criteria, test an additional 4 test samples. If any of these additional samples fail, the entirerepresented lot is rejected.

47-2.02 Materials47-2.02A GeneralConcrete leveling pads must be minor concrete.

Galvanize soil reinforcement, connecting elements, and other steel components in contact with the earthunder section 75-1.05.

Threaded ends of inspection wires for metallic soil reinforcement may be formed before or aftergalvanizing. Coat the final 4 inches of the wire with 2 applications of organic zinc-rich primer. Encase thethreaded end with a waterproof vinyl enclosure secured with a nylon tie. If the threaded end is galvanizedafter threading, clean the threads before painting.

Corrugated steel pipe must comply with section 66.

Perforated steel pipe underdrains and underdrain outlets and risers must comply with section 68-2.

Rock for rock slope protection at drain pipe outlets must be no. 3 backing and must comply with section72-2 of the Standard Specifications.


REVISION 0


Filter fabric must be Class A. Adhesive for bonding filter fabric to concrete panels must be commercialgrade.

Resin bonded cork for horizontal joints must comply with ASTM D 1752, Type II, with a compressive loadof at least 100 psi.

Pipe pins must comply with ASTM A 53/A 53M except the zinc coating of actual surface must average atleast 2.0 oz/sq ft and no individual specimen may be less than 1.8 oz/sq ft.

47-2.02B Face PanelsConcrete panels in freeze-thaw areas must comply with section 90-1.02I and contain at least 675 poundsof cementitious material per cubic yard.

47-2.02C Structure BackfillStructure backfill must:

1. Be free of organic material and substantially free of shale and other soft material of poor durability2. Not contain slag aggregate or recycled materials such as:

2.1. Glass2.2. Shredded tires2.3. Portland cement concrete rubble2.4. Asphaltic concrete rubble including asphaltic dust, sand, rock, grindings, slabs, and boulders2.5. Other unsuitable material as determined by the Engineer

3. MSE structure backfill shall have a minimum friction angle of 34 degrees.

For metallic soil reinforcement, structure backfill must comply with the requirements shown in thefollowing tables:

Gradation RequirementsSieve size Percentage passing California Test

6" 100 2023" 78-100 202No. 30 0-60 202No. 200 0-15 202

Property RequirementsTest Requirement California Test

Sand equivalent 12 minimum 217Plasticity index 6 maximum 204Minimum resistivity 3,000 ohm-cm 643Chlorides < 100 ppm 422Sulfates < 200 ppm 417pH 6.0 to 10.0 643NOTE : If 12 percent or less passes the no. 200 sieve and50 percent or less passes the no. 4 sieve, the SandEquivalent and Plasticity Index requirements do not apply.

For geosynthetic soil reinforcement, structure backfill must comply with the requirements shown in thefollowing tables:


REVISION 0


Gradation RequirementsSieve size Percentage passing California Test

2" 100 202No. 4 50-80 202No. 40 0-30 202No. 200 0-15 202

Property RequirementsTest Requirement California Test

Sand equivalent 12 minimum 217Plasticity index 6 maximum 204Durability Index 35 minimum 229pH 4.5 to 9.0 643

47-2.02D Permeable MaterialNot Used

47-2.02E Soil ReinforcementSteel wire must comply with ASTM A 82/A 82M. Welded wire reinforcement must comply with ASTM A185/A 185M.

For button-headed wires:

1. Buttons must be cold formed symmetrically about the axes of the wires2. Buttons must develop the minimum guaranteed ultimate tensile strength of the wire3. Do not use a cold forming process that causes indentations in the wire4. Button heads must not contain wide open splits, more than 2 splits per head, or splits nonparallel with

the axis of the wire

Couplers at wire reinforcement connections must be seamless steel sleeves applied over the button-headwires. Swage couplers with a hydraulic press. Couplers must develop the wire minimum tensile strengthwith a total slip of at most 3/16 inch.

Splice welded wire reinforcement along its length with mechanical couplers that develop the minimumtensile strength of the wire.

Identification, storage, and handling of geogrid reinforcement must comply with ASTM D 4873 and anyalternative system details. Protect the geogrid from chemicals, flames, welding sparks, and temperaturesless than 20 degrees F or greater than 140 degrees F. Do not allow foreign materials to come into contactwith or become affixed to the geogrid.

47-2.03 Construction47-2.03A GeneralWater for earthwork or for dust control within 500 feet of structures with metallic soil reinforcement mustcomply with section 90-1.02D.

Do not damage the unthreaded portion of the galvanized inspection wire.

47-2.03B Earthwork47-2.03B(1) GeneralGrade foundations level for a width equal to the length of soil reinforcement elements plus 1 foot or asshown. Compact foundation material to a relative compaction of at least 95 percent. Start wallconstruction activities after the Engineer accepts the compacted foundation area.

If ordered, remove unsuitable material.


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Place structure backfill simultaneously with erection of facing panels. Place and compact material withoutdistorting soil reinforcement or displacing facing panels. Place structure backfill at the front of the wallbefore backfilling more than 15 feet above the bottom of the lowermost face element.

If a mechanically stabilized embankment with soil reinforcement is to be constructed on an embankment,the embankment must attain at least 95 percent relative compaction within the limits established byinclined planes sloping 1.5:1 (horizontal:vertical) from lines 1 foot outside the bottom limits of themechanically stabilized embankment.

Start placing and compacting structure backfill 3 feet from the back face of wall panels. Progress towardthe free end of the soil reinforcement. Operate compaction equipment parallel to the wall facing. Placeand compact the remaining width of backfill behind wall panels after soil reinforcement is covered to adepth of 6 inches.

Do not use sheepsfoot or grid-type rollers within the limits of soil reinforcement. Use hand-held or hand-guided compacting equipment within 3 feet of facing panels.

Construct the structure backfill at each level of soil reinforcement to a plane 2 inches above the elevationof the soil reinforcement connection, starting 3 feet from the back of the face panel and extending for atleast the remaining length of soil reinforcement. Complete this grading before placing the next layer of soilreinforcement.

Grade backfill to drain away from the wall face at the end of each work shift. Use berms or ditches todirect runoff away from the wall site. Do not allow surface runoff from adjacent areas to enter theconstruction site.

47-2.03B(2) Soil ReinforcementPlace geogrid soil reinforcement in full-length sections.

Cover soil reinforcement with structure backfill during the same work shift that it is placed.

Tension soil reinforcement in the direction perpendicular to the wall face. Use sufficient force to removeslack in the connection and the soil reinforcement. Secure soil reinforcement in place before and duringcompaction.

Do not operate construction equipment directly on soil reinforcement. Maintain a layer of structure backfillat least 6 inches thick between soil reinforcement and any construction equipment.

Place structure backfill over geogrid soil reinforcement in lifts of at most 6 inches if using hand-operatedcompaction equipment and 8 inches if using heavy compaction equipment.

47-2.03B(3) Face PanelsVertical and horizontal panel alignment offset must not exceed 3/4 inch when measured along a 10-footstraightedge. The offset in any panel joint must not exceed 3/4 inch.

47-2.03C Filter FabricImmediately before placing filter fabric, filter fabric must be free of loose or extraneous material and sharpobjects that may damage the filter fabric.

Concrete panel surfaces to receive filter fabric must be dry and thoroughly cleaned.

Handle and place filter fabric under the manufacturer's instructions. Stretch, align, and place fabricwithout wrinkling.

Adjacent borders of filter fabric must be overlapped. Overlap rolls 6 to12inches. Place the preceding rollover the following roll in the direction the material is being spread.

Repair damaged filter fabric by placing a piece of filter fabric large enough to cover the damaged areaand provide at least a 12-inch overlap.


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Where structure backfill is to be placed on filter fabric, maintain at least 18 inches of structure backfillmaterial between filter fabric and equipment during placement. Do not operate equipment or vehiclesdirectly on filter fabric.

47-2.03D ConcretePlace concrete for leveling pads at least 24 hours before erecting face panels.

After placing backfill to 2 feet above inspection elements, dry pack voids in face panels with mortar undersection 51-1.03E(2) except the proportion of cementitious material to sand must be such that the mortarachieves a 28 day compressive strength of 1,000 to 1,500 psi.

48 TEMPORARY STRUCTURES48-1 GENERAL

48-1.01 GENERALSection 48 includes specifications for constructing temporary structures.

48-2 FALSEWORK48-2.01 GENERAL48-2.01A SummarySection 48-2 includes specifications for constructing falsework.

You must design, construct, and maintain falsework that:

1. Is safe and adequate2. Provides the necessary rigidity3. Supports the loads imposed4. Produces a finished structure that conforms to the lines and grades shown

48-2.01B Definitionspreviously welded splice: Splice made in a falsework member before the member is shipped to the job

site.

48-2.01C Submittals48-2.01C(1) GeneralSubmit a certificate of compliance for each delivery of structural composite lumber used in falsework.

Submit a letter of certification that certifies all components of the manufactured assemblies are used incompliance with the manufacturer's recommendations.

If requested (1) submit manufacturer's data for manufactured assemblies to verify manufacturer'srecommendations or (2) perform tests demonstrating adequacy of the proposed assemblies.

Submit field acceptance criteria for falsework piles with a calculated nominal resistance greater than 200tons. Base acceptance criteria on a wave equation analysis performed on dynamic monitoring offalsework pile driving. Analyses must be signed by an engineer who is registered as a civil engineer in theState. Submit acceptance criteria before falsework erection is complete.

Submit a letter of certification for all falsework members with field welded splices. The letter must certifythat all welding and NDT, including visual inspection, comply with the Contract and the welding standardshown on the shop drawings. The letter must be signed by an engineer who is registered as a civilengineer in the State. Submit the letter before placing any concrete on the falsework being certified.

Submit a welding certification for falsework members with previously welded splices. The certificationmust:

1. Itemize the testing and inspection methods used


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2. Include tracking and identifying documents for previously welded members3. Be signed by an engineer who is registered as a civil engineer in the State4. Be submitted before erecting the members

48-2.01C(2) Shop DrawingsSubmit shop drawings with supporting calculations for falsework.

Shop drawings and calculations must be signed by an engineer who is registered as a civil engineer inthe State if any of the following conditions apply:

1. Height of any portion of the falsework measured from the ground line to the soffit of thesuperstructure is more than 14 feet

2. Any individual falsework clear span is more than 16 feet3. Provisions for vehicular, pedestrian, or railroad traffic through the falsework are made

Shop drawings and calculations for falsework piles with a calculated loading capacity greater than 100tons must be designed by an engineer who is registered as a civil or geotechnical engineer in the State.

Submit 6 sets of falsework drawings and 2 sets of design calculations. Include the following:

1. Details of erection and removal activities.2. Methods and sequences of erection and removal, including equipment.3. Details for the stability of falsework during all stages of erection and removal activities.4. Superstructure placing diagram showing concrete placing sequence and construction joint locations.

If a schedule for placing concrete is shown, no deviation is allowed.5. Assumed soil bearing values for falsework footings.6. Maximum horizontal distance falsework piles may be pulled for placement under caps.7. Maximum deviation of falsework piles from vertical.8. Anticipated total falsework and form settlements, including footing settlement and joint take-up.9. Grade (E-value), species, and type of any structural composite lumber. Include manufacturer's

tabulated working stress values for the lumber.10. Design calculations including stresses and deflections in load carrying members.11. Provisions for complying with temporary bracing requirements.12. Welding standard used for welded members.

Submit separate drawings and calculations for each single bridge or portion of bridge.

For multi-frame bridges, submit a separate submittal for each frame.

If you submit multiple submittals at the same time or additional submittals before review of a previoussubmittal is complete:

1. You must designate a review sequence for submittals2. Review time for any submittal is the review time specified plus 15 days for each submittal of higher

priority still under review

You may revise authorized falsework shop drawings if there is sufficient time for the Department's reviewbefore construction starts on the revised section. The additional time will not be more than that originallyallowed.

For falsework over railways, authorization of falsework drawings is contingent upon the drawings beingsatisfactory to the railway company involved.

The licensed engineer signing the falsework drawings must certify that the falsework is constructed asshown in the authorized shop drawings before concrete is placed. The certification must include anynecessary testing to verify the ability of the falsework members to sustain the stresses required by thefalsework design. The licensed engineer may designate a representative to perform this certification asfollows:


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1. Where falsework contains openings for railroads, vehicular traffic, or pedestrians, the designatedrepresentative must (1) have at least 3 years of combined experience in falsework design orsupervising falsework construction and (2) be registered as a civil engineer in the State

2. For other falsework, the designated representative must have at least 3 years of combinedexperience in falsework design or supervising falsework construction

3. The Engineer may request you certify the experience of the designated representative and providesupporting documentation demonstrating the required experience

48-2.01D Quality Control and Assurance48-2.01D(1) GeneralNot Used

48-2.01D(2) Welding and Nondestructive TestingWelding must comply with AWS D1.1 or other recognized welding standard except (1) for previouslywelded splices and (2) if fillet welds are used where load demands are 1,000 lb or less per inch for each1/8 inch of fillet weld.

Perform NDT on splices made by field welding at the job site. You may use UT or RT. Each field weld andany repair made to a previously welded splice must be tested. You must select locations for testing. Thelength of a splice weld where NDT is to be performed must be a cumulative weld length equal to 25percent of the original splice weld length. The cover pass must be ground smooth at test locations.Acceptance criteria must comply with the specifications for cyclically loaded nontubular connectionssubject to tensile stress in clause 6 of AWS D1.1. If repairs are required in a portion of the weld, performadditional NDT on the repaired sections. The NDT method chosen must be used for an entire spliceevaluation, including any repairs.

For previously welded splices, you must determine and perform all necessary testing and inspectionrequired to certify the ability of the falsework members to sustain the design stresses.

48-2.01D(3) Design Criteria48-2.01D(3)(a) GeneralDesign falsework to resist the sum of the dead and live vertical loads and an assumed horizontal load.

Anticipated falsework settlement must not exceed 1 inch.

Design footings to carry the imposed loads without exceeding estimated soil bearing values or anticipatedsettlements.

Falsework spans for T-beam girders must not exceed 14 feet plus 8.5 times the T-beam girder depth.

Design falsework supporting deck slabs and overhangs on girder bridges so there is no differentialsettlement between the girders and the deck forms during deck concrete placement.

For individual steel towers with maximum leg loads exceeding 30 kips, design foundations to provideuniform settlement under all legs of each tower.

Design support systems for form panels supporting concrete deck slabs and overhangs on girder bridgesas falsework.

Temporary bracing must be designed to withstand all imposed loads during erection, construction andremoval of any falsework. Wind loads must be included in the design of the bracing or methods.

48-2.01D(3)(b) LoadsThe design load for falsework must consist of dead and live vertical loads, and an assumed horizontalload. The minimum total design load for any falsework is 100 psf, including members that supportwalkways for the combined live and dead load.

Dead loads must include the weight of concrete, reinforcing steel, forms, and falsework. Loads due toconcrete, reinforcing steel, and forms must be assumed to be at least:


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1. 160 pcf for normal concrete2. 130 pcf for lightweight concrete

Live loads must include:

1. Actual weight of any equipment to be supported by the falsework applied as concentrated loads at thepoints of contact

2. Uniform load of at least 20 psf applied over the area supported by the falsework3. Load of 75 lb/ft applied at the outside edge of deck overhangs

The assumed horizontal load the falsework bracing system must resist must be the sum of the actualhorizontal loads due to equipment, construction sequence or other causes, and a wind loading. Thehorizontal load in any direction must be at least 2 percent of the total dead load.

If the concrete is to be prestressed, design the falsework to support any increased or readjusted loadscaused by the prestressing forces.

Design the falsework with sufficient rigidity to resist the assumed horizontal load without considering theconcrete load.

For heavy-duty steel shoring or steel pipe column falsework with a vertical load capacity greater than 30kips per leg or column, the minimum horizontal wind loading must equal the sum of the products of thewind impact area, shape factor, and wind pressure value for each height zone. The wind impact area isthe total projected area of all elements in the tower face or falsework bent normal to the direction of theapplied wind. Use a shape factor of 2.2 for heavy-duty steel shoring and 1.0 for pipe column falsework.Use wind pressure values shown in the following table:

Height zone(feet above ground)

Wind pressure valueShores or columnsadjacent to traffic

At otherlocations

(psf) (psf)0–30 20 15

30–50 25 2050–100 30 25

Over 100 35 30

For all other falsework, the minimum horizontal wind loading must equal the sum of the products of thewind impact area and the wind pressure value for each height zone. The wind impact area is the grossprojected area of the falsework and any unrestrained portion of the permanent structure except for theareas between falsework bents or towers where diagonal bracing is not used. Use the wind pressurevalues shown in the following table:

Height zone(feet above

ground)

Wind pressure valueFor members over and bents

adjacent to traffic openingAt otherlocations

(psf) (psf)0–30 2.0 Q 1.5 Q30–50 2.5 Q 2.0 Q

50–100 3.0 Q 2.5 QOver 100 3.5 Q 3.0 Q

NOTES:Q = 1 + 0.2W, but not more than 10W=width of the falsework system in feet, measured inthe direction of the wind force


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Design falsework to support placement of the entire superstructure cross-section, except railing, at onetime. You may consider girder stems and connected bottom slabs self-supporting between falseworkposts if:

1. They are placed more than 5 days before the top slab2. The distance between falsework posts is at most 4 times the depth of the portion of the girder stem

placed in the 1st pour

Falsework for box girder structures with internal falsework bracing systems that use flexible memberscapable of withstanding only tensile forces must be designed to include (1) the vertical effects caused byelongation of the flexible member and (2) the design horizontal load combined with the dead and liveloads imposed by concrete placement for girder stems and connected bottom slabs. This requirementdoes not apply to falsework composed of individual steel towers that use flexible members capable ofwithstanding only tensile forces to resist overturning.

48-2.01D(3)(c) Stresses, Loadings, and Deflections48-2.01D(3)(c)(i) GeneralMaximum allowable stresses and loadings specified in section 48-2.01D(3)(c) are based on the use ofundamaged high-quality materials. Reduce stresses and loadings for materials of lesser quality.

48-2.01D(3)(c)(ii) TimberDesign timber connections under Caltrans' Falsework Manual.

The maximum allowable stresses, loadings, and deflections for timber are shown in the following table:

Property RequirementCompression perpendicularto the grain

450 psi

Compression parallel to thegrain

480,000/(L/d)² psi;1,600 psi maximum

Flexural stress1,800 psi; 1,500 psi maximum formembers with a nominal depth of8 inches or less.

Horizontal shear 140 psiAxial tension 1,200 psiDeflection due to concreteloading only

1/240 of span lengtha

Modulus of elasticity (E) 1.6 x 106 psiTimber piles 45 tonsNOTES:

L = unsupported length, inchesd = least dimension of a square or rectangular column or thewidth of a square of equivalent cross-sectional area for roundcolumns, inches

aDo not include deflection compensated for in camber strips

48-2.01D(3)(c)(iii) SteelExcept for flexural compressive stresses, design stresses for identified grades of steel must not exceedstresses specified in the AISC Steel Manual.

Except for flexural compressive stresses, design stresses for unidentified steel must not exceed thosespecified for steel complying with ASTM A 36/A 36M in the AISC Steel Manual or the following:


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Property RequirementTension, axial and flexural 22,000 psiCompression, axial 16,000 - 0.38(L/r)2 psia

Shear on gross section of webof rolled shapes

14,500 psi

Web yielding for rolled shapes 27,000 psiModulus of elasticity (E) 30 x 106 psiNOTES:

L = unsupported length, inchesr = radius of gyration of the member, inches

aL/r must not exceed 120

Design stresses and deflections for all grades of steel must not exceed the following:

Property RequirementCompression, flexural 12,000,000/[(L x d)/(b x t)] psia

Deflection due to concreteloading only

1/240 of the spanb

Modulus of elasticity (E) 30 x 106 psiNOTES:

L = unsupported length, inchesd = least dimension of rectangular columns or the width of asquare of equivalent cross-sectional area for round columns, orthe depth of beams, inchesb = width of the compression flange, inchest = thickness of the compression flange, inchesFy = specified minimum yield stress in psi

aNot to exceed (1) 22,000 psi for unidentified steel, (2) 22,000 psifor steel complying with ASTM A 36/A 36M, or (3) 0.6Fy for otheridentified steelbDo not include deflection compensated for in camber strips

48-2.01D(3)(c)(iv) Manufactured AssembliesDo not exceed the manufacturer's recommendations for loadings and deflections on jacks, brackets,columns, joists, and other manufactured devices, except the dead load deflection of joists at locationsother than under deck slabs between girders must not exceed 1/240 of their spans.

48-2.01D(3)(d) Special LocationsDesign and construct falsework over or adjacent to roadways or railroads that are open to traffic such thatthe falsework is stable if subjected to impact by vehicles.

Falsework posts at the following locations are considered adjacent to roadways or railroads:

1. Posts supporting members that cross over a roadway or railroad2. Posts located in the row of falsework posts nearest to the roadway or railroad and the horizontal

distance from the traffic side of the falsework to the edge of pavement or to a point 10 feet from thecenterline of track is less than the total height of the falsework and forms

The falsework design at the above locations must comply with section 48-2.01D(3) and the followingrequirements:

1. The vertical load used for the design of falsework posts and towers that support the portion of thefalsework over openings must be the greater of:1.1 150 percent of the design load calculated under section 48-2.01D(3)(b), not including any

increased or readjusted loads caused by prestressing forces


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1.2 Increased or readjusted loads caused by prestressing forces2. Falsework posts must be steel with a minimum section modulus about each axis of 9.5 cubic inches

or sound timbers with a minimum section modulus about each axis of 250 cubic inches.3. Each falsework post must be mechanically connected to the support footing at its base or laterally

restrained to withstand a force of at least 2,000 lb applied at the base of the post in any directionexcept toward the roadway or railroad track. Posts must be mechanically connected to the falseworkcap or stringer. The mechanical connection must resist a load in any horizontal direction of at least1,000 lb.

4. Mechanically connect (1) exterior falsework stringers, (2) stringers adjacent to the ends ofdiscontinuous caps, (3) stringers over points of minimum vertical clearance, and (4) every 5thremaining stringer to the falsework cap or framing. For falsework over railroads, mechanically connectall stringers to caps. Mechanical connections must resist at least a 500-lb load in any direction,including uplift on the stringer. Install connections before traffic passes under the span.

5. Connect timber bracing to falsework using at least 5/8-inch-diameter bolts or coil rod with a rootdiameter equal to that of the shank of a 5/8-inch-diameter bolt.

6. Falsework member clearances must be at least those shown in the following table:

Falseworkmember

ClearancesTo railing members, barriers,

and anchored temporary railingsTo unanchored

temporary railingsFootings 0'-3" 2'-0"Piles 1'-0" 2'-9"Other members 2'-0" 2'-9"

7. Falsework bents within 20 feet of the centerline of a railway track must be sheathed solid from 3 to 17feet above the track on the side facing the track. Sheathing must be plywood at least 5/8 inch thick orlumber at least 3/4 inch thick. Brace these bents to resist the required assumed horizontal load or5,000 lb, whichever is larger.

8. Provide clear openings through falsework as described.


48-2.03 CONSTRUCTION48-2.03A GeneralInstall temporary bracing as necessary to withstand all imposed loads during erection, construction, andremoval of any falsework.

The materials used in the falsework construction must be of the quality necessary to sustain the stressesrequired by the falsework design.

Install Type K temporary railing on both sides of vehicular openings through falsework. The Engineer mayorder you to install temporary railing at other falsework less than 12 feet from the edge of a traffic lane.

Temporary railings for vehicular openings must start 150 feet in advance of the falsework and extend pastthe falsework in the direction of adjacent traffic flow. For 2-way traffic openings, temporary railing mustextend at least 60 feet past the falsework in the direction of adjacent traffic flow.

Install temporary crash cushion modules as shown at the approach end of temporary railings located lessthan 15 feet from the edge of a traffic lane. For 2-way traffic openings install temporary crash cushionmodules at the departing end of temporary railings located less than 6 feet from the edge of a traffic lane.

The Engineer orders the location and length of railing and the type of flare to be used.

Install all temporary railing protecting falsework before erecting falsework. Do not remove temporaryrailing until authorized.


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48-2.03B FoundationsConstruct falsework on solid footings capable of supporting falsework loads. Protect footings fromsoftening and undermining. The Engineer may order you to verify the design soil bearing values do notexceed the soil capacity using load testing.

You may place falsework foundation pads and piles before shop drawings are authorized.

Falsework piles must be driven and the actual nominal pile resistance assessed under section 49.

48-2.03C ErectionConstruct falsework to support the loads imposed without settlement or take-up beyond that shown on thefalsework drawings.

Install the final bracing system before placing falsework members above stringers.

If falsework is over or adjacent to roadways or railroads, all details of the falsework system that contributeto horizontal stability and resistance to impact, except for bolts in bracing, must (1) be installed at the timeeach element of the falsework is erected and (2) remain in place until the falsework is removed.

If ordered, use camber strips to compensate for falsework deflection, vertical alignment, and anticipatedstructure deflection. The Engineer furnishes the amount of camber to be used in constructing falsework.

Install tell-tales that (1) are attached to the soffit forms and (2) can be read from the ground. Providesufficient tell-tales to allow the total settlement where concrete is being placed to be determined.

Construct deck slab forms between girders with no allowance for settlement relative to the girders.

Do not apply dead loads other than forms and reinforcing steel to falsework until authorized.

If (1) events occur that the Engineer determines will result in a structure that does not comply with thestructure as described or (2) settlements occur that are more than ±3/8 inch greater than those shown onthe falsework drawings, stop concrete placement and employ corrective measures satisfactory to theEngineer. If satisfactory measures are not provided before initial concrete set occurs, stop concreteplacement at a location ordered.

48-2.03D RemovalRemove falsework such that portions of falsework not yet removed remain stable at all times.

Except for concrete above the deck, do not release falsework supporting any span of a:

1. Simple span bridge before 10 days after the last concrete has been placed.2. Continuous or rigid frame bridge before 10 days after the last concrete has been placed in that span

and in adjacent portions of each adjoining span for a length equal to one-half of the span wherefalsework is to be released.

3. Simple span bridge or a continuous or rigid frame bridge until the supported concrete has attained acompressive strength of 2,600 psi or 80 percent of the specified strength, whichever is greater.

Do not release falsework for prestressed portions of structures until prestressing steel has beentensioned.

Do not remove falsework supporting any span of a continuous or rigid frame bridge until all requiredprestressing is complete (1) in that span and (2) in adjacent portions of each adjoining span for a lengthequal to at least one-half of the span where falsework is to be released.

Release falsework supporting spans of CIP girders, slab bridges, or culverts before constructing orinstalling railings or barriers on the spans unless authorized.

Remove falsework for arch bridges uniformly and gradually. Start at the crown and work toward thespringing. Remove falsework for adjacent arch spans concurrently.


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Do not release falsework that supports overhangs, deck slabs between girders, or girder stems that slope45 degrees or more from vertical before 7 days after deck concrete has been placed.

You may release falsework supporting the sides of girder stems that slope less than 45 degrees fromvertical before placing deck concrete if you install lateral supports. Lateral supports must be:

1. Designed to resist rotational forces on the girder stem, including forces due to concrete deckplacement

2. Installed immediately after each form panel is removed3. Installed before releasing supports for the adjacent form panel

Do not release falsework for bent caps supporting steel or PC concrete girders before 7 days after placingbent cap concrete. Do not erect girders onto bent caps until bent cap concrete has attained acompressive strength of 2,600 psi or 80 percent of the specified strength, whichever is greater.

Remove falsework for structural members subject to bending as specified for simple span bridges.

Do not release falsework for box culverts and other structures with decks lower than the roadwaypavement and span lengths of 14 feet or less until the last placed concrete has attained a compressivestrength of 1,600 psi. Curing of the concrete must not be interrupted. Falsework removal for other boxculverts must comply with the specifications for the release of bridge falsework.

Do not release falsework for arch culverts sooner than 40 hours after concrete has been placed.

Remove falsework piling to at least 2 feet below the original ground or streambed. Remove falseworkpiling driven within ditch or channel excavation limits to at least 2 feet below the bottom and side slopes ofthe excavated areas.

Dispose of falsework materials and work debris.

48-2.04 PAYMENTNot Used

48-3 TEMPORARY SUPPORTSNot Used

48-4 TEMPORARY DECKINGNot Used

48-5 JACKING SUPERSTRUCTURE48-5.01 GENERAL48-5.01A SummarySection 48-5 includes specifications for lowering the superstructure of the following bridges:

Bridge LocationMotor Bridge Span 1Palms Bridge Span 1Pico Bridge Span 1

You must (1) design and construct the temporary supports for the superstructure and (2) determine themethods and equipment for lowering the superstructure.


48-5.01C SubmittalsSubmit shop drawings with design calculations for the jacking support system. Submit 6 sets of shopdrawings and 2 sets of design calculations. Include the following:


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1. Descriptions and values of all loads, including construction equipment loads2. Descriptions of equipment to be used3. Details and calculations for jacking and supporting the structure4. Stress sheets, anchor bolt layouts, shop details, and erection and removal plans for the temporary

supports5. Assumed soil bearing values and design stresses for support footings, including anticipated

foundation settlement6. Details for bracing required during erection and removal7. Details of the displacement monitoring system, including equipment, location of control points, and

methods and schedule of taking measurements8. Details for jacking the structure if settlement occurs

Calculations must show a summary of computed stresses in the jacking support system and theconnections between the support system and the bridge superstructure. The computed stresses mustinclude the effect of the jacking sequence. Calculations must include a lateral stiffness assessment of thejacking support system.

Shop drawings and calculations must be signed by an engineer who is registered as a civil engineer inthe State.

For falsework over railways, authorization of shop drawings is contingent upon the drawings beingsatisfactory to the railway company involved.

48-5.01D Quality Control and Assurance48-5.01D(1) GeneralCalibrate each jack within 6 months of use and after each repair. Each jack and its gage must (1) becalibrated as a unit with the cylinder extension in the approximate position that it will be at the final jackingforce and (2) accompanied by a certified calibration chart. Each load cell must be calibrated. Calibrationmust be performed by an authorized laboratory.

48-5.01D(2) Displacement MonitoringMonitor and record vertical and horizontal displacements of the temporary supports and the existingstructure. Use vandal-resistant displacement monitoring equipment. Perform monitoring continuouslyduring jacking activities. Make monitoring records available at the job site during normal work hours.Monitoring records must be signed by an engineer who is registered as a civil engineer in the State.

As a minimum, monitor the existing structure at the supported bent and at the midspan of both adjoiningspans. Locate control points at each location near the center and at both edges of the superstructure. Asa minimum, take elevations at the following times:

1. Before starting jacking activities2. Immediately after completing jacking3. Before connecting the superstructure to the substructure4. After removing temporary supports

48-5.01D(3) Design CriteriaThe jacking support system must resist the structure dead load and lateral design forces shown, plus anyadditional loads from jacking equipment and activities. You must determine soil bearing values for supportfootings. If the jacking support stiffness exceeds the specified minimum stiffness, increase the lateraldesign forces to be compatible with the jacking support lateral stiffness.

Systems involving modifications to the bridge that impair the structural integrity, intended serviceability, ordesign capacity of the bridge are not allowed.


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48-5.02 MATERIALS48-5.02A MaterialsJacks used for the jacking supports system must be ENERPAC ESS Synchronous Lift System orapproved equal.

48-5.03 CONSTRUCTIONInstall the jacking support system under section 48-2.03C.

Equip each jack with a pressure gage or load cell for determining the jacking force. Each pressure gagemust have an accurately reading dial. Each load cell must be provided with an indicator to determine thejacking force.

Provide a redundant system of supports during jacking activities. The redundant system must includestacks of steel plates added as necessary to maintain the redundant supports within 1/4 inch of thejacking sill or corbels.

Before removing falsework, the jacking support system must (1) apply a force to the structure that is equalto the initial jacking load or the dead load shown and (2) hold that load until all initial compression andsettlement of the system is completed.

Lower the superstructure uniformly to the position shown. Lower the superstructure such that no distortionoccurs that would damage the superstructure. Distribute the load uniformly across each hinge, abutment,or bent. If authorized, place galvanized shims as necessary to provide uniform loading at bearing pads.

Stop jacking activities if unanticipated displacements, cracking, or other damage occurs. Apply correctivemeasures satisfactory to the Engineer.

After lowering, remove the jacking support system under section 48-2.03D. Remove attachments requiredfor lowering from the superstructure and apply the specified finish to concrete surfaces.

49 PILING49-1 GENERAL

49-1.01 GENERAL49-1.01A SummarySection 49-1 includes general specifications for constructing foundation piles.

49-1.01B Definitionscontrol zone: Zone that has the same subsurface profile and engineering properties as a corresponding

support location.

nominal driving resistance: Sum of (1) nominal resistance required to resist the factored axial loads and(2) driving resistance from unsuitable or scourable penetrated soil layers that do not contribute to thedesign resistance.

nominal resistance: Design capacity required to resist the factored axial loads.

pile structural capacity design: Design based on the nominal strength as defined in Article 8.1.3 of theCaltrans Bridge Design Specifications or the nominal resistance as defined in Article 1.3.2.1 of theAASHTO LRFD Bridge Design Specifications.

49-1.01C Submittals49-1.01C(1) GeneralBefore handling or installing piles at a location that is closer than the length of the pile being handled orinstalled to the edge of any traveled way open to public use, submit a work plan of the measures that willbe used to provide for the safety of traffic and the public.

Submit a VECP for revisions to specified tip elevations shown or installation methods.


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49-1.01C(2) Test BoringsIf test borings are specified in these specifications, submit the log of test borings and the test boringreport upon completion of all test borings. Submit 4 sets of the test boring report and the log of testborings to OSD, Documents Unit. The submittal must comply with the specifications for shop drawings.Notify the Engineer of your submittal. Include in the notification the date and contents of the submittal.

If corrections to the submittal are required, submit 1 set of the corrected test boring report and the log oftest borings to OSD, Documents Unit.

49-1.01D Quality Control and Assurance49-1.01D(1) GeneralPiling must have sufficient length to attain the specified tip elevation shown and extend into the pile cap orfooting.

49-1.01D(2) Determination of LengthYou may conduct additional foundation investigation, including installing and axial load testing ofadditional nonproduction indicator piling and performing test borings. The Engineer must authorizelocations of additional foundation testing. Notify the Engineer at least 5 business days before startingadditional foundation testing.

Complete additional foundation investigation before requesting revised specified pile tip elevations orrevisions to the described installation methods.

The Engineer does not authorize a revision to:

1. Specified installation methods where settlement or lateral loads control the design tip elevation2. Specified pile tip elevation above the design tip elevation shown for settlement or lateral loads3. Specified pile tip elevation where the tip elevation is controlled by liquefaction or scour

Indicator compression pile load testing must comply with ASTM D 1143. The pile must sustain the 1stcompression test load applied that is equal to the nominal driving resistance, with no more than 1/2-inchtotal vertical movement at the top of the pile measured relative to the top of the pile before the start ofcompression load testing.

Indicator tension pile load testing must comply with ASTM D 3689 except do not use the loadingapparatus described as "Load Applied to Pile by Hydraulic Jack(s) Acting at One End of Test Beam(s)Anchored to the Pile." The pile must sustain the 1st tension test load applied that is equal to the nominalresistance in tension shown with no more than 1/2-inch total vertical movement at the top of the pilemeasured relative to the top of the pile before the start of tension load testing.

Remove indicator piling as specified for removing portions of bridges.

49-1.01D(3) Load Test PilesWhere shown, complete load testing of each load test pile before drilling holes, casting piling, cuttingpiling to length, driving piling, and fabricating reinforcing steel cages for any piles represented by the loadtest pile.

Notify the Engineer at least 10 days before drilling or driving piles to be load tested.

Except in cofferdams, the bottom of the footing excavation must be level and dewatered before pile loadtesting. The excavation must be kept dewatered during load testing.

Install load test piles with the same type of equipment that is to be used for installation of production piles.

Load test piles must comply with the specifications for piling as described. Locate load test piles such thatthey may be cut off and become a part of the completed structure.

Remove load test and anchor piles that are not incorporated in the completed structure as specified forremoving portions of bridges.


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For load test anchorages in piles used as anchor piles:

1. HS threaded steel rods must comply with ASTM A 722 for uncoated, deformed, Type II, HS steelbars, including all supplementary requirements, except the maximum weight requirement does notapply.

2. Steel plates must comply with ASTM A 709/A 709M, Grade 36.3. Anchor nuts must hold the HS steel rods at a load producing a stress of not less than 95 percent of

the specified ultimate tensile strength of the HS steel rod.4. Pipe, couplings, and fittings must be commercially available materials of the types and ratings shown.

You may use additional cementitious material in load test and anchor piles.

You may use Type III cement in any load test and anchor pile not used as a part of the completedstructure.

Furnish labor, materials, tools, equipment, and incidentals as required to assist the Department in theinstallation, operation, and removal of Department-furnished steel load test beams, jacks, bearing plates,drills, and other test equipment.

The Department performs testing of load test piles when the concrete in the load test and anchor pileshas developed a compressive strength of at least 2,000 psi.

Allow the Department 15 days to perform pile load tests at each test location. Allow an additional 10 daysfor the Department to revise the specified tip elevations.

49-1.01D(4) Dynamic MonitoringSection 49-1.01D(4) applies if dynamic monitoring of driven piling is specified in these specifications.

The Department determines which piles from a control zone or support location will receive dynamicmonitoring.

The Department dynamically monitors driven piles using Department-furnished dynamic pile analyzermonitoring instruments.

The 4th paragraph of section 49-2.01A(4)(b) does not apply to driven piles if dynamic monitoring isrequired.

The Department conducts penetration and bearing analysis of dynamically monitored piles and developsbearing acceptance criteria curves for these piles. Penetration and bearing analyses are based on a waveequation analysis.

Except for load test and anchor piles, do not install production piles until the Engineer provides you withthe bearing acceptance criteria curves for any piles represented by the dynamically monitored piles.

Piles to be dynamically monitored must be:

1. Available to the Department at least 2 business days before driving.2. Safely supported at least 6 inches off the ground in a horizontal position on at least 2 support blocks.

If requested, rotate the piles on the blocks.3. Positioned such that the Department has safe access to the entire pile length and circumference for

the installation of anchorages and control marks for monitoring.

Prepare and drive piles to be dynamically monitored in the following sequence:

1. Before driving, rotate and align the pile in the driving leads as ordered by the Department.2. Temporarily suspend driving operations for approximately 15 minutes when the pile tip is 25 feet

above the specified tip elevation shown.3. During the 15 minute suspension, bolt the 1-pound instrument package securely to plugs or

expansion anchors previously installed in the pile by the Department. Connect electrical cables to theinstrument package as ordered by the Department.


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4. Resume driving operations as ordered by the Department. Suspend driving operations approximately1 foot above the specified tip elevation.

5. Remove the cables and instrument package from the pile and deliver them to the Engineer.6. The following business day, install the instrument package on the pile and attach the cables and

resume driving the pile to the specified tip elevation.7. Remove the cables and instruments from the monitored pile and deliver them to the Engineer.

Replace any damaged cables or instruments in kind that are damaged by your activities.

After the pile has been dynamically monitored:

1. Allow 15 days for the Department to revise the specified tip elevations and to provide bearingacceptance criteria curves.

2. If pile load testing is performed in addition to dynamic monitoring, allow 25 days for the Department torevise the specified tip elevations and to provide bearing acceptance criteria curves.

49-1.01D(5) Test BoringsSection 49-1.01D(5) applies if test borings are specified in these specifications.

Notify the Engineer at least 15 days before drilling test borings.

Drill test borings under the site supervision of, with the log of test borings stamped by, and with the testboring submittal signed by a geologist or civil engineer who is registered in the State and has at least 5years of geotechnical engineering experience with deep foundations in both soil and rock.

Drill test borings at the center of each pile location shown.

Drill test borings by rotary drill methods to a depth of at least 20 feet below the specified tip elevationshown. Test borings must be at least 3 inches in diameter.

Perform standard penetration tests in all soil types under ASTM D 1586 for each test boring at 5-footmaximum intervals and terminate when (1) bedrock is encountered, (2) 10 blows with no discernablesampler advancement is observed, or (3) ordered.

Core the bedrock:

1. Continuously with at least 90 percent core recovery. Rock must not be logged from drill cuttings. Rockquality designation must be made at 5-foot maximum intervals.

2. Using an outer and inner core barrel drilling system. The outer core barrel must be fitted with adiamond impregnated or polycrystalline drill bit and have an outside diameter of at least 3 inches. Thesplit inner tube core barrel must have an inside diameter of at least 2 inches.

Photograph the rock cores:

1. Before removal from the split inner tube barrels and placement into core boxes2. After core boxes are filled and before boxes are removed from the drilling platform

Rock core photographs must be in color, 5 by 7 inches, and labeled with the borehole number, sampleelevation, scale, and date and time of photograph.

Place the rock cores in rock core boxes that are labeled as specified in the Soil and Rock Logging,Classification and Presentation Manual. Include the support or pile location. Store rock core boxes on ornear the job site at an authorized location. Preserve and secure the rock core samples in a weather-protected facility until notified by the Engineer. Dispose of rock cores or transport them to GeotechnicalServices, as ordered.

The log of test borings and classifying and describing soils and rock must comply with the Soil and RockLogging, Classification and Presentation Manual available at the Geotechnical Services website. Use thesame version of the Soil and Rock Logging, Classification, and Presentation Manual shown. If no versionis shown, use the most current version of the manual.


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The test boring report must include:

1. Summary of drilling methods, drilling equipment, drill platforms, and drilling difficulties encountered2. Location map of the surveyed position of the test borings relative to the new pile locations in the

California Coordinate System and bridge stationing3. Bore hole surveying notes4. Photographs of rock cores5. Copies of original daily drilling notes

After the test boring report and the log of test borings have been authorized, allow 20 days for theEngineer to notify you of confirmation of or revisions to the specified pile tip elevations. Do not fabricate ormanufacture to length steel pipe piling, permanent steel casing, micropiling, and filled and unfilled steelcasing until you have been notified.


49-1.03 CONSTRUCTIONIf the Contract allows the use of more than 1 pile type, use the same type of pile for all piles within eachindividual footing.

Reinforced concrete extensions must comply with section 51.

Expect difficult pile installation due to the conditions shown in the following table:

Pile locationConditionsBridge Support location

Bundy Bridge Abutment 1, 4Bents 2,3

Anticipated groundwater and caving potential

Centinela Bridge Abutment 1,2 Anticipate groundwater, caving potential, wetslurry method requirements

Motor Bridge Abutment 1,2 Caving potentialOlympic Bridge Abutment 1,6 Bents

2,3,4,5Caving potential

Palms Bridge Abutment 1, 3Bents 2,

Anticipated groundwater and caving potential

Pico Bridge Abutment 1,10Bents 2,3,4,5, 6, 7,8, 9

Anticipated groundwater (Bents 7 and 8 only) andcaving potential

Sepulveda Bridge Abutment 1, 4Bents 2,3

Caving potential

49-1.04 PAYMENTNot used

49-2 DRIVEN PILINGNot Used

49-3 CAST-IN-PLACE CONCRETE PILING49-3.01 GENERAL49-3.01A GeneralSection 49-3 includes specifications for constructing CIP concrete piles.

CIP concrete piles include:

1. CIDH concrete piles2. CIDH concrete pile rock sockets


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3. Driven steel shells filled with concrete and reinforcement

Concrete must comply with section 51.

Bar reinforcing steel must comply with section 52.

49-3.01B Materials49-3.01B(1) GeneralUnless otherwise shown, concrete must have a minimum 28-day compressive strength of 4,500 psi.

Prequalify the concrete under section 90-1.01D(5)(b).

The combined aggregate grading must comply with the 3/8-inch maximum grading specified in section90-1.02C(4).

49-3.01B(2) Mass ConcreteSection 49-3.01B(2) applies to CIP concrete piles with a diameter greater than 8 feet.

The quantity of cementitious material must comply with the values shown in the following table:

Pile diameter (D)(feet)

Maximum quantity ofcementitious material

(lb/cu yd)8 < D 10 750

10 < D 14 720

Cementitious material must comply with section 90-1.02B(3), except at least 25 percent of the totalcementitious material must be fly ash.

For piles with a diameter greater than 14 feet, concrete must comply with the specifications for massconcrete in section 51-6.

49-3.01C ConstructionExcept for CIDH concrete piles constructed under slurry, construct CIP concrete piles such that theexcavation methods and the concrete placement procedures provide for placing the concrete againstundisturbed material in a dry or dewatered hole.

Place and secure reinforcement symmetrically about the axis of the pile. Securely block the reinforcementto provide the minimum clearance shown between the reinforcing steel cage and the sides of the drilledhole or steel shell.

Steel shells and dewatered drilled holes must be clean and free of water and debris before reinforcementand concrete are placed.

Provide a suitable light to the Engineer for inspecting the entire length of the steel shell or dewatered holebefore placing reinforcement and concrete.

The methods used to place the concrete must prevent segregation.

Concrete must not be allowed to fall from a height greater than 8 feet without the use of adjustable lengthpipes or tubes unless the flow of concrete is directed into the center of the hole and the concrete is notallowed to strike the reinforcement, reinforcement bracing, and other objects in the hole.

Vibrate concrete in the upper 15 feet of CIP concrete piles.

After placing concrete, cure the temporarily exposed surfaces of the CIP concrete piles under section 51-1.03H.


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49-3.02 CAST-IN-DRILLED-HOLE CONCRETE PILING49-3.02A General49-3.02A(1) SummarySection 49-3.02 includes specifications for constructing CIDH concrete piles and CIDH concrete pile rocksockets.

49-3.02A(2) Definitionsdry hole:

1. Except for CIDH concrete piles specified as end bearing, a drilled hole that:1.1. Accumulates no more than 12 inches of water in the bottom of the drilled hole during a period

of 1 hour without any pumping from the hole during the hour.1.2. Has no more than 3 inches of water in the bottom of the drilled hole immediately before placing

concrete.2. For CIDH concrete piles specified as end bearing, a drilled hole free of water without the use of

pumps.

49-3.02A(3) Submittals49-3.02A(3)(a) GeneralIf plastic spacers are proposed for use, submit the manufacturer's data and a sample of the plasticspacer. Allow 10 days for review.

49-3.02A(3)(b) Pile Installation PlanSubmit a pile installation plan. Include complete descriptions, details, and supporting calculations for thefollowing:

1. Concrete mix design, certified test data, and trial batch reports.2. Drilling or coring methods and equipment.3. Proposed method for casing installation and removal, if necessary.4. Methods for placing, positioning, and supporting bar reinforcement.5. Methods and equipment for determining:

6.1 Depth of concrete6.2 Theoretical volume of concrete to be placed, including the effects on volume if casings are

withdrawn6.3 Actual volume of concrete placed

6. Methods and equipment for verifying the bottom of the drilled hole is clean before placing concrete.7. Methods and equipment for preventing upward movement of reinforcement, including the means of

detecting and measuring upward movement during concrete placement activities.

For concrete placed under slurry, include complete descriptions, details, and supporting calculations inthe pile installation plan for:

1. Concrete batching, delivery, and placing systems, including time schedules and capacities. Timeschedules must include the time required for each concrete placing activity at each pile.

2. Concrete placing rate calculations. If requested, base calculations on the initial pump pressures orstatic head on the concrete and losses throughout the placing system, including anticipated head ofslurry and concrete to be displaced.

3. Suppliers’ test reports on the physical and chemical properties of the slurry and any proposed slurrychemical additives, including MSDSs.

4. Slurry testing equipment and procedures.5. Methods of removal and disposal of excavation, slurry, and contaminated concrete, including removal

rates.6. Methods and equipment for slurry agitating, recirculating, and cleaning.


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49-3.02A(3)(c) Inspection Pipe Coupler LogWhere inspection pipes are required, submit a log of the locations of inspection pipe couplers as aninformational submittal upon completion of concrete placement in the hole.

49-3.02A(3)(d) Concrete Placement LogContractor performing CIDH drilling/concrete placement shall provide a concrete placement log within 1business day of completion of concrete placement in the hole. The concrete placement log shall then besubmitted as an informational submittal.

49-3.02A(3)(e) Coring Logs and Concrete CoresIf coring is performed under section 49-3.02A(4), submit coring logs and concrete cores.

49-3.02A(3)(f) Testing ReportIf you perform testing on a rejected pile, submit this additional information in a report. The report must besealed and signed by an engineer who is registered as a civil engineer in the State. Allow the Department10 days for review and analysis of this report.

49-3.02A(3)(g) Mitigation PlansFor each rejected pile, submit a mitigation plan for repair, supplementation, or replacement. Themitigation plan must:

1. Comply with the specifications for shop drawings.2. Be sealed and signed by an engineer who is registered as a civil engineer in the State. This

requirement is waived for either of the following conditions:2.1 The proposed mitigation will be performed under the current Caltrans' -published version of

ADSC Standard Mitigation Plan 'A' - Basic Repair without exception or modification.2.2 The Engineer determines that the rejected pile does not require mitigation due to structural,

geotechnical, or corrosion concerns, and you elect to repair the pile using the current Caltrans'-published version of ADSC Standard Mitigation Plan 'B' - Grouting Repair without exception ormodification.

The most recent version of the ADSC Standard Mitigation Plan is available at the following Web site:

http://www.dot.ca.gov/hq/esc/geotech/ft/adscmitplan.htm

Pile mitigation plans must include:

1. Designation and location of the rejected pile.2. Review of the structural, geotechnical, and corrosion design requirements of the rejected pile.3. Step by step description of the mitigation work to be performed, including drawings if necessary.4. Assessment of how the proposed mitigation work addresses the structural, geotechnical, and

corrosion design requirements of the rejected pile.5. Methods for preservation or restoration of existing earthen materials.6. List of any affected facilities. Include methods and equipment to be used for the protection of these

facilities during mitigation.7. Your name and the names of any subcontractors on each sheet.8. List of materials with quantity estimates for the mitigation work and a list of personnel with their

qualifications who will be performing the mitigation work.

For rejected piles to be repaired, include the following in the pile mitigation plan:

1. Assessment of the nature and size of the anomalies in the rejected pile2. Provisions for access for additional pile testing, if requested

For rejected piles to be replaced or supplemented, include the following in the pile mitigation plan:

1. Proposed location and size of additional piles


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2. Structural details and calculations for any modification to the structure to accommodate thereplacement or supplemental piles

Replacement piles must comply with the Contract for CIDH concrete piles.

49-3.02A(3)(h) Mitigation ReportIf repairs are performed, submit a mitigation report as an informational submittal within 10 days ofcompletion of the repair. The report must state exactly what repair work was performed and quantify thesuccess of the repairs relative to the submitted mitigation plan. The mitigation report must be sealed andsigned by an engineer who is registered as a civil engineer in the State. The mitigation report mustinclude your name and the names of any subcontractors on each sheet.

49-3.02A(4) Quality Control and Assurance49-3.02A(4)(a) GeneralNot Used

49-3.02A(4)(b) Preconstruction MeetingSchedule and hold a preconstruction meeting for CIDH concrete pile construction (1) at least 5 businessdays after submitting the pile installation plan and (2) at least 10 days before the start of CIDH concretepile construction. You must provide a facility for the meeting.

The meeting must include the Engineer, your representatives, and any subcontractors involved in CIDHconcrete pile construction.

The purpose of this meeting is to:

1. Establish contacts and communication protocol between you and your representatives, anysubcontractors, and the Engineer

2. Review the construction process, acceptance testing, and anomaly mitigation of CIDH concrete piles

The Engineer will conduct the meeting. Be prepared to discuss the following:

1. Pile placement plan, dry and wet2. Acceptance testing, including gamma-gamma logging, cross-hole sonic logging, and coring3. Pile Design Data Form4. Mitigation process5. Timeline and critical path activities6. Structural, geotechnical, and corrosion design requirements7. Future meetings, if necessary, for pile mitigation and pile mitigation plan review8. Safety requirements, including Cal/OSHA and Tunnel Safety Orders

49-3.02A(4)(c) Concrete Test BatchSection 49-3.02A(4)(c) applies if concrete is placed under slurry.

Before placing concrete under slurry, produce a concrete test batch and transport it to the job site underthe same conditions and in the same time frame that is anticipated during the placement of concrete inthe piles.

At the job site, place the test batch concrete in an excavated hole or suitable container to allow for testing.Placing concrete under slurry is not required. The test batch must demonstrate that the proposed mixdesign will achieve the minimum required slump after the specified set period.

Do not vibrate or agitate the concrete during the set period.

The Engineer tests the concrete for slump under California Test 556. In addition to meeting the specifiednominal slump, the slump of the concrete must comply with the requirements shown in the following table:


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Slump RequirementsTime required to place

concretea, TMinimum set period before

testingbSlump, after set

periodT 2 hours 2T 7 inchesT > 2 hours T + 2 hours 7 inches

aAs described in the pile installation planbThe set period starts at the start of concrete placement.

After testing, dispose of the concrete test batch.

49-3.02A(4)(d) Acceptance Testing49-3.02A(4)(d)(i) GeneralSection 49-2.03A(4)(d) applies to CIDH concrete piles except for piles (1) less than 24 inches in diameteror (2) constructed in dry holes or holes dewatered without the use of temporary casing to control groundwater.

The Department performs acceptance testing using gamma-gamma logging to test the concrete densityof the pile for homogeneity.

After notification by the Engineer of pile acceptance, dewater the inspection pipes and cored holes and fillthem with grout. Grout must comply section 50-1.02C. Fill inspection pipes and holes using grout tubesthat extend to the bottom of the pipe or hole or into the grout already placed.

49-3.02A(4)(d)(ii) Vertical Inspection PipesInstall vertical inspection pipes for acceptance testing as follows:

1. Inspection pipes must be schedule 40 PVC pipe complying with ASTM D 1785 with a nominal pipesize of 2 inches. Watertight PVC couplers complying with ASTM D 2466 are allowed to facilitate pipelengths in excess of those commercially available. Log the location of the inspection pipe couplerswith respect to the plane of pile cutoff.

2. Cap each inspection pipe at the bottom. Extend the pipe from 3 feet above the pile cutoff to thebottom of the reinforcing cage. Provide a temporary top cap or similar means to keep the pipes cleanbefore testing. If pile cutoff is below the ground surface or working platform, extend inspection pipesto 3 feet above the ground surface or working platform.

3. If any changes are made to the pile tip, extend the inspection pipes to the bottom of the reinforcingcage.

4. Install inspection pipes in a straight alignment, parallel to the main reinforcement, and securelyfastened in place to prevent misalignment during installation of the reinforcement and placing ofconcrete in the hole. Construct CIDH concrete piles such that the relative distance of inspection pipesto vertical steel reinforcement remains constant.

5. Fill inspection pipes with water upon completion of the concrete placement to prevent debonding ofthe pipe.

6. Inspection pipes must be completely clean, dry, and unobstructed at the time of testing providing a 2-inch diameter clear opening.

7. Provide safe access to the tops of the tubes.

After placing concrete and before requesting acceptance testing, test each inspection pipe in thepresence of the Engineer by passing a 1-1/4-inch-diameter by 4.5-foot-long rigid cylinder through thelength of pipe.

If an inspection pipe fails to pass the rigid cylinder:

1. Immediately fill all inspection pipes in the pile with water2. Core a nominal 2-inch diameter hole through the concrete for the entire length of the pile for each

inspection pipe that does not pass the rigid cylinder3. Locate cored holes as close as possible to the inspection pipes they are replacing and no more than

5 inches clear from the reinforcement


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Coring must not damage the pile reinforcement. Core holes using a double wall core barrel system with asplit tube type inner barrel. Coring with a solid type inner barrel is not allowed. Coring methods andequipment must provide intact cores for the entire length of the pile. Preserve cores and identify themwith the exact location the core was recovered from the pile.

The coring activity must be logged by an engineering geologist or civil engineer licensed in the State andexperienced in core logging. Coring logs must comply with Caltrans' Soil and Rock Logging,Classification, and Presentation Manual. Coring logs must include core recovery, rock quality designation,locations of breaks, and complete descriptions of inclusions and voids encountered during coring.

The Department evaluates the portion of the pile represented by the cored hole based on the submittedcore logs. If the Department determines that a pile is anomalous based on the coring logs, the pile isrejected.

If inspection pipes are not shown:

1. Include in the pile installation plan a plan view drawing of the pile showing reinforcement andinspection pipes.

2. Place inspection pipes radially around the pile, inside the outermost spiral or hoop reinforcement andno more than 1 inch clear of the outermost spiral or hoop reinforcement.

3. Place inspection pipes around the pile at a uniform spacing not exceeding 33 inches measured alongthe circle passing through the centers of inspection pipes. Use at least 2 inspection pipes per pile.Place inspection pipes to provide the maximum diameter circle that passes through the centers of theinspection pipes while maintaining the spacing required herein.

4. Place inspection pipes at least 3 inches clear of the vertical reinforcement. Where the verticalreinforcement configuration does not allow this clearance while achieving radial locationrequirements, maximize the distance to vertical rebar while still maintaining the requirement for radiallocation.

Where the dimensions of the pile reinforcement do not allow inspection pipes to be placed as specifiedabove, submit a request for deviation before fabricating pile reinforcement.

49-3.02A(4)(d)(iii) Gamma-Gamma LoggingThe Department performs gamma-gamma logging under California Test 233.

Separate reinforcing steel as necessary to allow the Department access to the inspection pipes.

After requesting testing and providing access to the piles, allow 15 days for the Department to performthe testing and to prepare and provide the pile acceptance test report.

During testing, do not perform construction activities within 25 feet of any gamma-gamma logging activity.

If the Department determines that a pile is anomalous under California Test 233, part 5C, the pile isrejected.

49-3.02A(4)(d)(iv) Rejected PilesIf a pile is rejected:

1. Suspend concrete placement in the remaining piles2. Revise the pile installation plan and submit it to the Engineer3. Do not resume concrete placement until the revised pile installation plan is authorized

Allow 30 days for the Department to determine whether the rejected pile requires mitigation and toprovide this information to you. Day 1 of the 30 days is the 1st day after access has been provided to theDepartment to perform acceptance testing.

The Department may perform additional tests to further evaluate a rejected pile. These tests may includecrosshole sonic logging and other means of inspection selected by the Department. The pile acceptancetest report will indicate if the Department intends to perform any additional testing and when the testing


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will be performed. Allow the Department 20 additional days for a total of 50 days to perform these testsand to provide supplemental results.

You may perform testing on the rejected pile.

The Department determines whether the rejected pile requires mitigation due to structural, geotechnical,or corrosion concerns. The Department considers the estimated size and location of the anomaly andpotential effects on the design. The Department provides you with the conclusions of this analysis fordeveloping the mitigation plan.

If a rejected pile requires mitigation or you elect to repair a rejected pile that does not require mitigation,submit a mitigation plan for the repair, supplementation, or replacement of the rejected pile.

If the Engineer determines that it is not feasible to repair the rejected pile, submit a mitigation plan forreplacement or supplementation of the rejected pile.

If the Engineer determines it is not feasible to use one of ADSC's standard mitigation plans to mitigate thepile, schedule a meeting and meet with the Engineer before submitting a nonstandard mitigation plan.

The meeting attendees must include your representatives and the Engineer's representatives involved inthe pile mitigation. The purpose of the meeting is to discuss the type of pile mitigation acceptable to theDepartment.

Provide the meeting facility. The Engineer conducts the meeting.

49-3.02B Materials49-3.02B(1) GeneralNot Used

49-3.02B(2) ConcreteConcrete placed under slurry must:

1. Have a nominal slump equal to or greater than 7 inches. The nominal and maximum slump andpenetration specifications in section 90-1.02G(6) do not apply to concrete placed under slurry.

2. Contain not less than 675 pounds of cementitious material per cubic yard and be proportioned toprevent excessive bleed water and segregation.

In a freeze-thaw area, the formed portion of CIDH concrete piles must contain not less than 675 poundsof cementitious material per cubic yard.

49-3.02B(3) Aggregate GradingsFor concrete placed under slurry, the combined aggregate grading must comply with the 3/8-inchmaximum grading specified in section 90-1.02C(4).

49-3.02B(4) Permanent Steel CasingsPermanent steel casings must comply with section 49-2.02.

49-3.02B(5) GroutGrout used to backfill casings must comply with section 50-1.02C, except:

1. Grout must consist of cementitious material and water, and may contain an admixture if authorized.Cementitious material must comply with section 90-1.02B, except SCMs are not required. Theminimum cementitious material content of the grout must not be less than 845 lb/cu yd of grout.

2. Aggregate must be used to extend the grout as follows:2.1 Aggregate must consist of at least 70 percent fine aggregate and approximately 30 percent

pea gravel, by weight.2.2 Fine aggregate must comply with section 90-1.02C(3).2.3 Size of pea gravel must be such that 100 percent passes the 1/2-inch sieve, at least 90 percent

passes the 3/8-inch sieve, and not more than 5 percent passes the no. 8 sieve.


REVISION 0


3. California Test 541 is not required.4. Grout is not required to pass through a sieve with a 0.07-inch maximum clear opening before being

introduced into the grout pump.

49-3.02B(6) Slurry49-3.02B(6)(a) GeneralNot Used

49-3.02B(6)(b) Mineral SlurryMineral slurry must be mixed and thoroughly hydrated in slurry tanks. Sample and test slurry from theslurry tanks before placement in the drilled hole.

Recirculate or continuously agitate slurry in the drilled hole.

For recirculated slurry:

1. Remove drill cuttings from the slurry before discharging the slurry back into the drilled hole.2. Sample and test slurry at least every 2 hours after starting its use until tests show that the samples

taken from the slurry tank and from near the bottom of the hole have consistent specified properties.Once consistent properties have been achieved, sample slurry at least twice per shift as long as thespecified properties remain consistent.

For non-recirculated slurry:

1. Sample and test slurry from the drilled hole at least every 2 hours after starting its use. Sample theslurry at mid-height and near the bottom of the hole.

2. Recirculate slurry if tests show samples taken from mid-height and near the bottom of the hole do nothave consistent specified properties.

Sample and test slurry before final cleaning of the bottom of the hole and again just before placingconcrete. Sample the slurry at mid-height and near the bottom of the hole. Cleaning of the bottom of thehole and placement of the concrete must not start until tests show that the samples have consistentspecified properties.

Mineral slurry must comply with the requirements shown in the following table:

Mineral Slurry Requirementsa

Property Test method ValueDensity

Mud Weight (Density),API 13B-1section 1

Before placement in the drilled holeand during drilling

64.3–69.1 pcfb

Before final cleaning andimmediately before placing concrete

64.3–75.0 pcf b

ViscosityMarsh Funnel and Cup.API 13B-1, section 2.2

Bentonite 28–50 sec/qt

Attapulgite 28–40 sec/qtpH Glass electrode pH meter or

pH paper8–10.5

Sand content Sand,API 13B-1, section 5Before final cleaning and

immediately before placing concrete 4.0 percent

aSlurry temperature must be at least 40 degrees F when tested.bIf authorized, you may use slurry in salt water. The allowable density of slurry in salt watermay be increased up to 2 pcf.


REVISION 0


Remove any caked slurry on the sides or bottom of hole before placing reinforcement.

When concrete is not placed immediately after placing reinforcement, the reinforcement must be removedand cleaned of slurry, the sides of the drilled hole must be cleaned of caked slurry, and the reinforcementagain placed in the hole for concrete placement.

49-3.02B(6)(c) Synthetic SlurrySynthetic slurry material and property requirements are specified in these specifications.

Do not use synthetic slurries in holes drilled in primarily soft or very soft cohesive soils as determined bythe Engineer.

A manufacturer's representative must:

1. Provide technical assistance for the use of their material2. Be at the job site before introduction of the synthetic slurry into the drilled hole3. Remain at the job site until released by the Engineer

Sample and test synthetic slurries:

1. When the slurry temperature is at least 40 degrees F.2. At mid-height and near the bottom of the hole.3. During drilling to verify the slurry properties.4. When drilling is complete but before final cleaning of the bottom of the hole. When samples comply

with the requirements shown in the tables for the slurry material selected, clean the bottom of the holeof any loose or settled material.

5. After final cleaning and before placing concrete.

The synthetic slurry must be one of the materials shown in the following table:

Material ManufacturerSlurryPro CDP KB Technologies Ltd.

3648 FM 1960 West, Suite 107Houston, TX 77068

(800) 525-5237Super Mud PDS Company

c/o Champion Equipment Company8140 East Rosecrans Ave.

Paramount, CA 90723(562) 634-8180

Shore Pac GCV CETCO Drilling Products Group1350 West Shure Drive

Arlington Heights, IL 60004(847) 392-5800

Terragel or NovagelPolymer

Geo-Tech Drilling Fluids220 N. Zapata Hwy, Suite 11A

Laredo, TX 78043(210) 587-4758

Use synthetic slurries in compliance with the manufacturer's instructions. Synthetic slurries shown in theabove table may not be appropriate for a given job site.

Synthetic slurries must comply with Caltrans' requirements for synthetic slurries to be included in theabove table. The requirements are available from Caltrans’ Offices of Structure Design, P.O. Box 168041,MS# 9-4/11G, Sacramento, CA 95816-8041.

SlurryPro CDP synthetic slurry must comply with the requirements shown in the following table:


REVISION 0


SLURRYPRO CDPProperty Test Value

Density Mud Weight (density),API 13B-1,section 1

During drilling 67.0 pcfa

Before final cleaning and immediatelybefore placing concrete

64.0 pcfa

Viscosity Marsh Funnel and Cup.API 13B-1, section 2.2During drilling 50–120 sec/qt


70 sec/qt

pH Glass electrode pH meteror pH paper

6.0–11.5

Sand content, percent by volume Sand,API 13B-1, section 5Before final cleaning and immediately

before placing concrete 0.5 percent

aIf authorized, you may use slurry in salt water. The allowable density of slurry in salt water maybe increased by 2 pcf.Slurry temperature must be at least 40 degrees F when tested.

Super Mud synthetic slurry must comply with the requirements shown in the following table:

SUPER MUDProperty Test Value

Density Mud Weight (Density),API 13B-1,section 1



64.0 pcfa



60 sec/qt


8.0–10.0





REVISION 0


Shore Pac GCV synthetic slurry must comply with the requirements shown in the following table:

SHORE PAC GCVProperty Test Value




64.0 pcfa



57 sec/qt


8.0–11.0




Terragel or Novagel Polymer synthetic slurry must comply with the requirements shown in the followingtable:

TERRAGEL OR NOVAGEL POLYMERProperty Test Value




64.0 pcfa



104 sec/qt


6.0–11.5




49-3.02B(6)(d) Water SlurryYou may use water as slurry if a casing is used for the entire length of the drilled hole.

Water slurry properties must comply with the requirements shown in the following table:


REVISION 0


Water Slurry RequirementsProperty Test Value

Density Mud Weight (Density),API 13B-1section 1


63.5 pcf a

Sand content Sand,Before final cleaning andimmediately before placing concrete

API 13B-1, section 5 0.5 percent

aIf authorized, you may use salt water slurry. The allowable density of the slurry may beincreased by 2 pcf.

49-3.02B(7) Not Used49-3.02B(8) SpacersSpacers must comply with section 52-1.03D, except you may use plastic spacers.

Plastic spacers must:

1. Comply with sections 3.4 and 3.5 of the Concrete Reinforcing Steel Institute's Manual of StandardPractice

2. Have at least 25 percent of their gross plane area perforated to compensate for the difference in thecoefficient of thermal expansion between the plastic and concrete

3. Be of commercial quality

49-3.02B(9)–49-3.02B(10) Not Used49-3.02C Construction49-3.02C(1) GeneralExcept for CIDH concrete piles for sound walls and retaining walls, you may propose to increase thediameter and revise the pile tip elevation of CIDH concrete piles with a diameter less than 2 feet.

For CIDH concrete piles for sound walls and retaining walls, you may propose to increase the diameter ofCIDH concrete piles with a diameter less than 2 feet, except that pile tip elevations must not be revised.

49-3.02C(2) Drilled HolesThe axis of the drilled hole must not deviate from plumb more than 1-1/2 inches per 10 feet of length.

During excavation, do not disturb the foundation material surrounding the pile. Equipment or methodsused for excavating holes must not cause quick soil conditions or cause scouring or caving of the hole.

For rock sockets, equipment and drill methods must not result in soften materials on the borehole walls.

After excavation has started, construct the pile expeditiously to prevent deterioration of the surroundingfoundation material from air slaking or from the presence of water. Remove and dispose of deterioratedfoundation material, including material that has softened, swollen, or degraded, from the sides and thebottom of the hole.

Just before placing reinforcement or concrete, clean the bottom of the hole to remove any loose sand,gravel, dirt, and drill cuttings.

After placing reinforcement and before placing concrete in the hole, if caving occurs or deterioratedfoundation material accumulates on the bottom of the hole, clean the bottom of the hole. You must verifythat the bottom of the hole is clean.

Remove water that has infiltrated the hole before placing concrete. Do not allow fluvial or drainage waterto enter the hole.


REVISION 0


Portions of the hole may be enlarged, backfilled with slurry cement backfill, concrete, or other material,and redrilled to the diameter shown to control caving. Backfill material at enlarged piles must bechemically compatible with concrete and steel, be drillable, and have the necessary strength required forthe conditions.

Dispose of material resulting from placing concrete.

49-3.02C(3) Temporary Steel CasingsFurnish temporary steel casings where shown and where necessary to control water or to prevent quicksoil conditions or caving of the hole. Place temporary casings tight in the hole.

Section 11-3 does not apply to temporary steel casings.

Temporary casings must be:

1. Watertight and of sufficient strength to withstand the loads from installation, removal, lateral concretepressures, and earth pressures

2. Noncorrugated with smooth surfaces3. Clean and free of hardened concrete

Remove the temporary casing during concrete placement. In a dewatered hole, maintain the concrete inthe casing at a level of at least 5 feet above the bottom of the casing or (2) at a level above the bottom ofthe casing adequate to prevent displacement of the concrete by material from outside the casing,whichever is greater.

If slurry is not used, do not withdraw the temporary casing until the concrete head in the casing is greaterthan the groundwater head outside of the casing. Maintain this positive concrete head during withdrawalof the casing.

You may vibrate or hammer the temporary casing to (1) assist in removal of the casing from the hole, (2)prevent lifting of the reinforcement, and (3) prevent concrete contamination.

The withdrawal of casings must not leave voids or cause contamination of the concrete with soil or othermaterials.

49-3.02C(4) ReinforcementReinforcement for CIDH concrete piles with increased diameters and revised tip elevations must complywith the following:

1. Size and number of the reinforcing bars and hoops, the percentage of bars required to extend to thepile tip, and the size and pitch of spiral reinforcement must be the same as shown for the originalpiles.

2. Required length of the spiral reinforcement and of any reinforcing bars that do not extend to the piletip must be at least the length that would have been required for the original specified or ordered tipelevation.

3. Diameter of the spiral or hoop reinforcement must remain the same as required for the original pile ormay be increased to provide not less than the concrete cover required for the original pile. Providepositive means to ensure that the reinforcement is centered in the pile.

Unless otherwise shown, the bar reinforcing steel cage must have at least 3 inches of clear covermeasured from the outside of the cage to the sides of the hole or casing.

Place spacers at least 5 inches clear from any inspection tubes.

Place plastic spacers around the circumference of the cage and at intervals along the length of the cage,as recommended by the manufacturer.

49-3.02C(5) Permanent Steel Casing InstallationSection 49-2.01A(4)(b) does not apply to permanent steel casings.


REVISION 0


For permanent steel casings placed in a drilled hole:

1. The casings must be watertight and of sufficient strength to prevent damage and to withstand theloads from installation activities, drilling and tooling equipment, lateral concrete pressures, and earthpressures.

2. Use spacers to center the casing inside the drilled hole. You may weld spacers to the outside of thecasing.

3. Fill voids in the annular space between the casing and the soil with grout.4. Place grout from the bottom of the casing using grout tubes. Place grout continuously until all voids

have been filled and the grout reaches the top of the casing. Free fall of the grout from the top to thebottom of the casing is not allowed.

5. Pump grout into the annular space such that the grout head is maintained uniformly around thecasing and no visible evidence of water or air is ejected at the top of the grout.

6. Place grout tubes along the circumference of the casing with a minimum of 4 grout tubes per casing.The spacing of the grout tubes must not exceed 4 feet.

7. Extend grout tubes to within 1 foot of the bottom of the casing.

If the Engineer lowers the permanent steel casing tip elevation:

1. CIDH concrete pile, including bar reinforcing steel and inspection pipes, must extend to that sameelevation.

2. Tip elevation of the rock socket must extend to maintain the length of the rock socket into rock asshown.

49-3.02C(6) Optional Construction JointSection 49-3.02C(6) applies to CIDH concrete piles where an optional construction joint is shown.

If you choose to construct the optional construction joint and a permanent steel casing is not shown, youmust furnish and install a permanent casing. The permanent casing must:

1. Be watertight and of sufficient strength to prevent damage and to withstand the loads from installationprocedures, drilling and tooling equipment, lateral concrete pressures, and earth pressures.

2. Extend at least 5 feet below the construction joint. If placing casing into rock, the casing must extendat least 2 feet below the construction joint.

3. Not extend above the top of the drilled hole or final grade whichever is lower.4. Not increase the diameter of the CIDH concrete pile more than 2 feet.5. Be installed by impact or vibratory hammers, oscillators, rotators, or by placing in a drilled hole.

Casings placed in a drilled hole must comply with section 49-3.02C(5).

Section 49-2.01A(4)(b) does not apply to permanent casings.

49-3.02C(7) Placing ConcreteSection 51-1.03D(3) does not apply to CIDH concrete piles.

You may construct CIDH concrete piles 24 inches in diameter or larger by excavating and depositingconcrete under slurry.

Form, finish, and cure portions of CIDH concrete piles shown to be formed under section 51.

49-3.02C(8) Placing Concrete Under SlurrySection 49-3.02C(8) applies if placing concrete under slurry.

After placing reinforcement and before placing concrete in the drilled hole, if drill cuttings settle out of theslurry, clean the bottom of the drilled hole. Verify that the bottom of the drilled hole is clean.

Carefully place concrete in a compact, monolithic mass, using a method that prevents washing of theconcrete. Vibrating of concrete is not required.


REVISION 0


Placing concrete must be a continuous activity lasting no longer than the time specified for each concreteplacing activity at each pile in your pile installation plan.

The delivery tube system must consist of one of the following:

1. A tremie tube or tubes, each of which is at least 10 inches in diameter, fed by one or more concretepumps

2. One or more concrete pump discharge tubes, each fed by a single concrete pump

The delivery tube system must consist of watertight tubes with sufficient rigidity to keep the tube endsalways in the mass of concrete placed. If only 1 delivery tube is used to place the concrete, place the tubenear the center of the hole. Multiple tubes must be uniformly spaced in the hole.

Internal bracing for the steel reinforcing cage must accommodate the delivery tube system. Do not usetremies for piles without space for a 10-inch-diameter tube.

During concrete placement, provide a fully operational standby concrete pump at the job site that isadequate to complete the work in the time specified in the pile installation plan.

Do not allow concrete to fall into the slurry during concrete placing activities. Cap the delivery tube with awatertight cap, or plug the tube above the slurry level with a good quality, tight fitting, moving plug that willexpel the slurry from the tube as the tube is charged with concrete. The cap or plug must be designed torelease as the tube is charged.

Extend the pump discharge or tremie tube to the bottom of the hole before charging the tube withconcrete. After charging the tube with concrete, induce the flow of concrete through the tube by slightlyraising the discharge end.

During concrete placement:

1. Embed the tip of the delivery tube within 6 inches of the bottom of the hole until 10 feet of concretehas been placed. Maintain the embedment of the tip at least 10 feet below the top surface of theconcrete

2. Do not rapidly raise or lower the delivery tube3. Maintain the slurry level 10 feet above the piezometric head or within 12 inches of the top of the

drilled hole, whichever is higher

If the seal is lost or the delivery tube becomes plugged and must be removed:

1. Withdraw and clean the tube.2. Cap the tip of the tube to prevent slurry from entering.3. Restart the operation by pushing the capped tube 10 feet into the concrete and then reinitiating the

flow of concrete.

Maintain a log of concrete placement for each drilled hole. The log must:

1. Show the pile location, tip elevation, dates of excavation and concrete placement, total quantity ofconcrete placed, length and tip elevation of any casing, and details of any hole stabilization methodand materials used.

2. Include an 8-1/2 by 11 inch graph of concrete placed versus depth of hole filled as follows:2.1 Label the graph with the pile location, tip elevation, cutoff elevation, and the dates of

excavation and concrete placement.2.2 Plot the graph continuously throughout concrete placement. Plot the depth of drilled hole filled

vertically with the pile tip at the bottom and the quantity of concrete placed horizontally.2.3 Take readings at each 5 feet of pile depth, and indicate the time of the reading on the graph.

If a temporary casing is used, maintain concrete placed under slurry at a level at least 5 feet above thebottom of the casing. The withdrawal of the casing must not cause contamination of the concrete withslurry.


REVISION 0


The equivalent hydrostatic pressure inside the casing must be greater than the hydrostatic pressure onthe outside of the casing.

Dispose of material resulting from using slurry.

50 PRESTRESSING CONCRETE50-1.01 GENERAL50-1.01A SummarySection 50 includes specifications for prestressing concrete.


50-1.01C Submittals50-1.01C(1) GeneralSubmit certifications to the Department and test samples to METS.

50-1.01C(2) CertificationsSubmit the certifications specified in the following:

1. ASTM A 416/A 416M for uncoated seven-wire steel strand2. ASTM A 722/A 722M for uncoated HS steel bars3. ASTM A 882/A 882M for filled epoxy-coated seven-wire prestressing steel strand

Include with each certification:

1. Representative load-elongation curve for each size and grade of strand and for each size of bar2. Copy of the QC tests performed by the manufacturer

50-1.01C(3) Shop DrawingsSubmit shop drawings for the prestressing system proposed for use to OSD, Documents Unit. Notify theEngineer of the submittal. Include in the notification the date and list of contents of the submittal.

For initial review, submit:

1. 6 sets for railroad bridges2. 8 sets for railroad bridges if the project includes a BNSF Railway underpass3. 4 sets for other structures

After initial review, submit from 6 to 12 sets to OSD, Documents Unit, as requested.

The shop drawings must show complete details and substantiating calculations of the method andmaterials proposed for use in the prestressing activities, including the addition or rearrangement ofreinforcing steel.

The details must outline the method and sequence of stressing and must include:

1. Complete specifications and details of the prestressing steel and anchorage system.2. Jacking stresses.3. Type of ducts.4. Proposed arrangement of the prestressing steel in the members.5. Exact location of anchorage system components, ducts, and other related elements. Show duct

location data, including elevations at least every 1/8th point of the span for each span.6. Elongation calculations.7. All other data pertaining to the prestressing.

Each shop drawing submittal must consist of drawings for a single bridge or portion of a bridge. Formultiframe bridges, each frame must have a separate shop drawing submittal.


REVISION 0


Allow the following time for review of the shop drawings:

1. 60 days for railroad bridges2. 45 days for other structures

For railroad bridges, authorization of the shop drawings is contingent upon the drawings beingsatisfactory to the railway company involved.

50-1.01C(4) Test SamplesSubmit test samples for the materials to be used as shown in the following table:

Material Number of testsamples

Test sample description

Uncoated stranda 1 4-foot-long sample from each reel or packEpoxy-coated strand:

Uncoated stranda 1 4-foot-long sample of uncoated strand removed from eachreel or pack before coating

Coated stranda 4 5-foot-long sample from each reel or pack of coatedstrand

Epoxy powder 1 8-ounce sample from each batchb

Epoxy patchingmaterial

1 8-ounce sample from each batchb

Bara 1 7-foot-long sample of each size for each heatBar couplera 1 Coupler from each lot of couplers with two 4-foot-long

barsc

Anchorageassembliesa

1 Anchorage assembly from each lot of anchorageassemblies

aRandomly selected by the Engineer.bPackaged in an airtight container and identified with the manufacturer's name and batch number.cSubmit coupler and bar samples assembled. The bars must be from the same bar heats to be used inthe work.

Sample under the ASTM specified for testing the sample.

With each bar or strand test sample, include a certificate from the manufacturer stating the minimumguaranteed ultimate tensile strength of each bar or strand test sample.

Before submitting test samples to METS:

1. Identify each test sample by location and Contract number with weatherproof markings2. Attach a completed Sample Identification Card to each test sample

Allow 45 days for the Department's testing.

Obtain the Department's authorization of the material before incorporating it into the work.

50-1.01D Quality Control and Assurance50-1.01D(1) GeneralThe following items must be on the Authorized Material List:

1. Post-tensioning prestressing systems2. Organic zinc-rich primer


REVISION 0


For accurate identification, (1) assign an individual lot number and (2) tag each lot of the following itemsto be shipped to the job site or casting site:

1. Bars of each size from each heat2. Strand from each reel or pack3. Anchorage assemblies4. Bar couplers

The Department rejects any unidentified prestressing steel, anchorage assemblies, or bar couplersreceived at the job site or casting site.

50-1.01D(2) Quality Assurance TestingThe Department tests the test samples for compliance with section 50-1.02B.

The Department tests the efflux time of grout under California Test 541.

The Department may verify the prestressing force:

1. Using Department-furnished load cells for post-tensioning of prestressing steel2. Under California Test 677 for pretensioning prestressing steel

The Department determines the reduction of area of each test sample bar with the deformationsremoved. The deformations are removed by machining the bar no more than necessary to remove thedeformations over a length of 12 inches.

50-1.01D(3) Equipment and CalibrationEquip each hydraulic jack used to tension prestressing steel with 2 pressure gages or 1 pressure gageand a load cell.

Each jack body must be permanently marked with the ram area.

Each pressure gage must be fully functional and have an accurately reading dial at least 6 inches indiameter.

Each load cell must be calibrated and have an indicator that can be used to determine the force in theprestressing steel.

The range of each load cell must be such that the lower 10 percent of the manufacturer's rated capacity isnot used in determining the jacking force.

Calibrate jacking equipment as follows:

1. Calibrate each jack and its gage as a unit with the cylinder extension in the approximate position thatit will be at the final jacking force.

2. Each jack used to tension prestressing steel permanently anchored at 25 percent or more of itsspecified minimum ultimate tensile strength must be calibrated within 1 year of use and after eachrepair. You must:1.1. Schedule the calibration of the jacking equipment1.2. Verify that the jack and supporting systems are complete, with proper components, and are in

good operating condition1.3. Mechanically calibrate the gages with a dead weight tester or other authorized means before

calibration of the jacking equipment1.4. Provide enough labor, equipment, and material to (1) install and support the jacking and

calibration equipment and (2) remove the equipment after the calibration is complete1.5. Plot the calibration results

3. Each jack used to tension prestressing steel permanently anchored at less than 25 percent of itsspecified minimum ultimate tensile strength must be calibrated by an authorized laboratory within 6months of use and after each repair.


REVISION 0



50-1.02B Prestressing SteelUncoated strand must comply with ASTM A 416/A 416M

Epoxy-coated strand must comply with ASTM A 882/A 882M, grit impregnated coating, including AnnexA1.

Bars must comply with ASTM A 722/A 722M, Type II, including all supplementary requirements, exceptthe maximum weight requirements do not apply. The reduction of area of the bars with the deformationsremoved must be at least 20 percent.

If couplers are used to extend bars:

1. Assembled units must have a tensile strength of at least the manufacturer's minimum guaranteedultimate tensile strength of the bars. If the test sample does not meet this requirement, the heat ofbars and lot of couplers represented by the sample will be rejected.

2. Location of couplers in the member must be authorized.

Protect the prestressing steel against physical damage and rust or other results of corrosion at all times,from manufacture to grouting or encasing in concrete.

Package prestressing steel in containers or shipping forms that protect the steel against physical damageand corrosion during shipping and storage.

Except for epoxy-coated strand, a corrosion inhibitor that prevents rust or other results of corrosion mustbe (1) placed in the container or shipping form, (2) incorporated in a corrosion-inhibitor-carrier-typepackaging material, or (3) applied directly to the steel if authorized.

Corrosion inhibitors must not have a deleterious effect on the steel, concrete, or bond strength of the steelto concrete.

Clearly mark each shipping container or form with:

1. Statement that the package contains prestressing steel2. Type of corrosion inhibitor used3. Date packaged

Immediately replace or restore any damaged container or shipping form to its original condition.

Do not store epoxy-coated strand within 1,000 feet of ocean or tidal water for more than 2 months.

The Engineer rejects prestressing steel that has sustained physical damage.

The Engineer may reject prestressing steel that has developed visible rust or other results of corrosion.

Patching material for epoxy-coated strand must be:

1. Furnished by the manufacturer of the epoxy powder2. Applied under the manufacturer's instructions3. Compatible with the original epoxy powder material4. Inert in concrete

50-1.02C GroutGrout must consist of cement and water and may contain an admixture if authorized.

Cement must comply with section 90-1.02B(2)

Water must comply with section 90-1.02D.


REVISION 0


Admixtures must comply with section 90, except admixtures (1) must not contain chloride ions in excessof 0.25 percent by weight and (2) may be dispensed in solid form.

Mix the grout as follows:

1. Add water to the mixer followed by cement and any admixture.2. Mix the grout with mechanical mixing equipment that produces a uniform and thoroughly mixed grout.3. Do not exceed 5 gallons of water per 94 lb of cement. Retempering of grout is not allowed.4. Agitate the grout continuously until the grout is pumped.

The efflux time of grout immediately after mixing must be at least 11 seconds.

50-1.02D DuctsDucts for prestressing steel must:

1. Be galvanized rigid ferrous metal2. Be fabricated with either welded or interlocked seams, except galvanizing of the welded seams is not

required3. Be mortar tight4. Have sufficient strength to maintain their correct alignment during placing of concrete5. Have positive metallic connections at joints between sections that do not result in angle changes at

the joints6. Have waterproof tape at the connections7. Have bends that are not crimped or flattened8. Have ferrous metal or polyolefin transition couplings connecting the ducts to anchorage system

components. Ferrous metal transition couplings need not be galvanized9. Have an inside diameter of at least:

9.1. 2.5 times the net area of the prestressing steel for multistrand tendons that will be placed bythe pull-through method

9.2. 2.0 times the net area of the prestressing steel for multistrand tendons that will not be placedby the pull-through method

10. Have an inside diameter of at least 3/8 inch larger than the diameter of the bar11. Have an outside diameter not exceeding 50 percent of the girder web width

Furnish all ducts or anchorage assemblies with pipes or other suitable connections for the injection ofgrout after prestressing.

50-1.02E VentsVent all ducts having a vertical duct profile change of 6 inches or more. Place vents within 6 feet of everyhigh point in the duct profile. Vents must:

1. Be at least 1/2-inch-diameter standard pipe or suitable plastic pipe.2. Be connected to ducts using metallic or plastic structural fasteners. Plastic components must not

react with the concrete or enhance corrosion of the prestressing steel and must be free from watersoluble chlorides.

3. Be mortar tight and taped as necessary.4. Provide a means for injection of grout through the vents and for sealing the vents.

50-1.02F Flushing WaterWater used for flushing ducts must contain 0.1 pound of quicklime (calcium oxide) or slaked lime (calciumhydroxide) per gallon of water. Use only oil-free compressed air to blow out ducts.

50-1.02G SheathingSheathing for debonding prestressing strand must:

1. Be split or un-split flexible polymer plastic tubing1. Have a minimum wall thickness of 0.025 inch2. Have an inside diameter exceeding the maximum outside diameter of the strand by 0.025 to 0.14 inch


REVISION 0


Split sheathing must overlap at least 3/8 inch.

Waterproofing tape used to seal the ends of the sheathing must be flexible adhesive tape.

The sheathing and waterproof tape must not react with the concrete, coating, or steel.

50-1.03 CONSTRUCTION50-1.03A General50-1.03A(1) GeneralIf authorized, you may:

1. Apply a portion of the total prestressing force to a PC member before the member has obtained theconcrete strength shown

2. Move the member after applying the portion of prestressing force

Except for epoxy-coated strand, prestressing steel installed in members before placing and curing of theconcrete must be continuously protected against rust or other results of corrosion until grouted. Protectthe steel by using a corrosion inhibitor placed in the ducts or applied to the steel in the duct.

After final fabrication of the strand, do not perform any electric welding on the prestressing steel. If electricwelding is performed on or near members containing prestressing steel, attach the welding grounddirectly to the steel being welded.

50-1.03A(2) Epoxy-Coated StrandCover epoxy-coated strand with an opaque polyethylene sheeting or other suitable protective material toprotect the strand from exposure to sunlight, salt spray, and weather. For stacked coils, drape theprotective covering around the perimeter of the stack. The covering must be adequately secured andallow for air circulation around the strand to prevent condensation under the covering.

Cut epoxy-coated strand using an abrasive saw.

Patch all visible damage to the epoxy coating caused by shipping, job site handling, installation, or cuttingof ends, under ASTM A 882/A 882M.

50-1.03A(3) DuctsAccurately place prestressing ducts. Securely fasten the ducts in place to prevent movement of the ductsduring concrete placement.

After installation, cover the duct ends to prevent water or debris from entering.

50-1.03B Prestressing50-1.03B(1) GeneralTension the prestressing steel using hydraulic jacks. The force in the prestressing steel must be at leastthe value shown.

After seating, the maximum tensile stress in the prestressing steel must not exceed 75 percent of theminimum ultimate tensile strength shown.

50-1.03B(2) Post-Tensioned Members50-1.03B(2)(a) GeneralBefore placing forms for deck slabs of box girder bridges, demonstrate that any prestressing steel placedin the ducts is free and unbonded. If no prestressing steel is in the ducts, demonstrate that the ducts areunobstructed before placing the forms.

If prestressing steel is installed after the concrete is placed, demonstrate that the ducts are free of waterand debris immediately before installing the steel.


REVISION 0


Before post-tensioning any member, demonstrate that the prestressing steel is free and unbonded in theduct.

The Engineer must witness all demonstrations.

If requested, for verification of the force in the prestressing steel, furnish the resources necessary toinstall and support the Department's testing equipment at the prestressing steel location and to removethe equipment after the testing is complete.

Conduct the tensioning process such that the force being applied and the elongation of the prestressingsteel can be measured at all times.

The maximum temporary tensile strength in the prestressing steel of post-tensioned members must notexceed 75 percent of the specified minimum ultimate tensile strength of the prestressing steel.

If steam curing is used for precast members, do not install prestressing steel for post-tensioning until thesteam curing is completed.

If non-epoxy-coated prestressing steel is installed in the ducts after completion of concrete curing, andtensioning and grouting are completed within 10 days after the installation, then (1) rust that may formduring this period is not cause for rejection of the steel and (2) the use of a corrosion inhibitor in the ductis not required following installation.

Do not tension the prestressing steel of post-tensioned members until (1) at least 10 days after the lastconcrete has been placed in the member and (2) the concrete has attained the compressive strengthdescribed.

Distribute the prestressing force of post-tensioned bridge girders with an approximately equal quantity ineach girder and place the force symmetrically about the centerline of the structure. In slabs, distribute theprestressing force uniformly across the slab.

Sequence the stressing of post-tensioned bridge girders such that no more than 1/2 of the prestressingforce in any girder is applied before an equal force is applied in the adjacent girders. The maximumtemporary force variation between girders must not exceed the prestressing force of the largest tendonused in all girders. Do not apply an eccentric force about the centerline of the structure that exceeds 1/6of the total prestressing force at any time during the prestressing.

50-1.03B(2)(b) LossesNot Used

50-1.03B(2)(c) Anchorages and DistributionThe ends of post-tensioned prestressing steel must be secured with a permanent type anchoring system.

The anchorage system for post-tensioning must:

1. Hold the prestressing steel at a force producing a stress of at least 95 percent of the specifiedultimate tensile strength of the steel

2. Permanently secure the ends of the prestressing steel

You may omit the steel distribution plates or assemblies if you use an anchorage device of a type that issufficiently large and that is used in conjunction with a steel grillage embedded in the concrete thateffectively distributes the compressive stresses to the concrete.

If loop tendon anchorages are used, enclose the anchorages in ducts for their entire length.

Where the end of a post-tensioned assembly is not to be covered by concrete, recess the anchoragesystem such that the ends of the prestressing steel and all parts of the anchorage system are at least 2inches inside of the end surface of the members unless a greater embedment is shown. After post-tensioning, fill the recesses with concrete and finish flush.

The concrete used to fill the recess must be the same as that used for the structure.


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Distribute the anchorage load to the concrete by using a post-tensioning system.

The load from the anchorage system must be effectively distributed to the concrete such that:

1. Concrete bearing stress directly underneath the plate or assembly does not exceed 3,300 psi2. When the prestressing steel is tensioned to 95 percent of its specified ultimate tensile strength:

2.1 Bending stress in the plate material or assembly material does not exceed the yield point of thematerial

2.2 No visible distortion is evident in the anchorage plate

50-1.03B(2)(d) Bonding and Grouting50-1.03B(2)(d)(i) GeneralBond the post-tensioned prestressing steel to the concrete by completely filling the entire void spacebetween the duct and the prestressing steel with grout.

Ducts must be clean and free from water and deleterious materials that would impair bonding of the groutor interfere with grouting procedures.

Grout must pass through a screen with 0.07-inch maximum clear openings before being introduced intothe grout pump.

Prevent the leakage of grout through the anchorage assembly by positive mechanical means.

Pump grout through the duct as follows:

1. Continuously waste grout at the outlet until no visible slugs or other evidence of water or air is ejectedand the efflux time of ejected grout is at least 11 seconds

2. Close the outlet valve and hold the pumping pressure momentarily3. Close the valve at the inlet while maintaining the pressure

If hot weather conditions will contribute to quick stiffening of the grout, cool the grout by authorizedmethods as necessary to prevent blockages during pumping activities.

If freezing weather conditions are anticipated during and following the placement of grout, provideadequate means to protect the grout in the ducts from damage by freezing.

After completing duct grouting activities:

1. Abrasive blast clean and expose the aggregate of concrete surfaces where concrete is to be placedto cover and encase the anchorage assemblies

2. Remove the ends of vents 1 inch below the roadway surface

50-1.03B(2)(d)(ii) Grouting EquipmentGrouting equipment must be:

1. Capable of grouting at a pressure of at least 100 psi2. Equipped with a pressure gage having a full-scale reading of not more than 300 psi

Where vents are required, furnish standby flushing equipment capable of developing a pumping pressureof 250 psi and of sufficient capacity to flush out any partially grouted ducts.

Fit grout injection pipes, ejection pipes, and vents with positive mechanical shutoff valves capable ofwithstanding the pumping pressures. Do not remove or open valves until the grout has set. If authorized,you may substitute mechanical valves with suitable alternatives after demonstrating their effectiveness.

50-1.03B(2)(e) Debonding Prestressing StrandsWhere shown, debond prestressing strands by encasing the strands in plastic sheathing along the entirelength shown and sealing the ends of the sheathing with waterproof tape.


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Distribute the debonded strands symmetrically about the vertical centerline of the girder. The debondedlengths of pairs of strands must be equal.

Do not terminate debonding at any one cross section of the member for more than 40 percent of thedebonded strands or 4 strands, whichever is greater.

Thoroughly seal the ends with waterproof tape to prevent the intrusion of water or cement paste beforeplacing the concrete.

50-1.03B(3) Pretensioned MembersIf prestressing steel for pretensioning is placed in the stressing bed and is exposed to the elements formore than 36 hours before encasement in concrete, protect the steel from contamination or corrosionusing authorized measures.

Do not cut or release prestressing steel in pretensioned members until the concrete in the member hasattained a compressive strength of at least the value shown or 4,000 psi, whichever is greater. If epoxy-coated strand is used, do not cut or release the steel until the temperature of the concrete surroundingthe strand is less than 150 degrees F and falling.

If requested, check individually-tensioned strands for loss of prestress not more than 48 hours beforeplacing concrete for the members, using authorized methods and equipment. Strands showing a loss ofprestress of more than 3 percent must be retensioned to the original computed jacking force.

If prestressing steel in pretensioned members is tensioned at a temperature appreciably lower than theestimated temperature of the concrete and the prestressing steel at the time of initial set of the concrete,the calculated elongation of the prestressing steel must be increased to compensate for the loss in stress.

The maximum temporary tensile stress in the prestressing steel of pretensioned members must notexceed 80 percent of the specified minimum ultimate tensile strength of the prestressing steel.

Perform the cutting and releasing of prestressing steel in pretensioned members in such an order thatlateral eccentricity of prestress is a minimum.

Anchor the prestressing steel at stresses that will result in the ultimate retention of jacking forces at leastequal to those shown.

Cut off pretensioned prestressing steel flush with the end of the member. After cutting the steel, clean andpaint the exposed ends of the steel and a 1-inch strip of adjoining concrete as follows:

1. Wire brush or abrasive blast clean to remove all dirt and residue on the metal and concrete surfaces.2. Immediately after cleaning, apply 1 application of organic zinc-rich primer to the surfaces, except

apply 2 applications to surfaces that will not be covered by concrete or mortar. Do not use aerosolcans. Mix the paint thoroughly when applying and work into any voids in the prestressing steel.

51 CONCRETE STRUCTURES51-1 GENERAL

51-1.01 GENERAL51-1.01A SummarySection 51-1 includes general specifications for constructing concrete structures, including bridges,approach slabs, culverts, retaining walls, minor structures, and other structures.

Sliding joints, waterstops, and strip waterstops must comply with section 51-2.

Elastomeric bearing pads must comply with section 51-3.

Falsework for constructing concrete structures must comply with section 48-2.

You may use RSC only where the specifications allow the use of RSC.


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51-1.01B Definitionsform panel: Continuous section of form facing material, unbroken by joint marks, against which concrete

is placed.

opening age: Minimum age at which an element constructed with RSC may be opened to traffic.

pier column: Extension of a column or pier into bedrock material.

51-1.01C Submittals51-1.01C(1) GeneralIf requested, submit concrete form design and materials data for each forming system.

Submit a deck placement work plan for concrete bridge decks.

For colored concrete, submit technical data, manufacturer's specifications, and a work plan for mixing,delivery, placement, finishing, and curing of the concrete.

If the methacrylate crack treatment is performed within 100 feet of a residence, business, or public space,submit a public safety plan that includes the following:

1. Public notification letter with a list of delivery and posting addresses. The letter must describe thework to be performed and state the treatment work locations, dates, and times. Deliver the letter toresidences and businesses within 100 feet of overlay work and to local fire and police officials notless than 7 days before starting overlay activities. Post the letter at the job site.

2. Airborne emissions monitoring plan. A CIH certified in comprehensive practice by the American Boardof Industrial Hygiene must prepare and execute the plan. The plan must have at least 4 monitoringpoints including the mixing point, application point, and point of nearest public contact. Monitorairborne emissions during overlay activities.

3. Action plan for protecting the public if levels of airborne emissions exceed permissible levels.4. Copy of the CIH's certification.

After completing methacrylate crack treatment activities, submit results from monitoring productionairborne emissions as an informational submittal.

51-1.01C(2) Permanent Steel Deck FormsSubmit 3 sets of shop drawings for permanent steel deck forms. Include in the submittal:

1. Layout plan2. Grade of steel3 Physical and section properties of members4. Method of support and grade adjustment5. Method for accommodating skew6. Methods of sealing against grout leaks

51-1.01C(3) Bonding MaterialsSubmit a certificate of compliance for each shipment of the material.

51-1.01C(4) Rapid Strength ConcreteFor RSC, submit the mix design at least 10 days before use. Include in the submittal:

1. Compressive strength test results for prequalification of RSC at age of break, at 3 days, and at 28days

2. Opening age in hours3. Proposed aggregate grading4. Mix proportions of cementitious material, aggregate, and water5. Types and quantities of chemical admixtures, if used6. Range of ambient temperatures over which the mix design will achieve the required minimum

compressive strength


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7. Source of materials

51-1.01C(5) Chemical AdhesivesSubmit a certificate of compliance for chemical adhesive stating compliance with ICC AC 58 and CaltransAugmentation/Revisions to ICC AC 58. Revisions to ICC AC 58 are on the Authorized Material List.

Submit chemical adhesive manufacturer's installation procedures and warnings or precautions as aninformational submittal at least 2 business days before starting work.


51-1.01D(2) Rapid Strength ConcretePrequalify RSC before use. Prequalification of a RSC mix design includes determining the opening ageand attaining the minimum specified 28-day compressive strength.

Prequalify RSC under section 90-1.01D(5)(b).

Determine the opening age of the RSC mix design as follows:

1. Fabricate at least 5 test cylinders to be used to determine the age of break.2. Immediately after fabrication of the 5 test cylinders, store the cylinders in a temperature medium of 70

± 3 degrees F until the cylinders are tested.3. Determine the age of break to attain an average strength of the 5 test cylinders.4. Opening age is the age of break plus 1 hour.

The average strength of the 5 test cylinders must be at least 1,200 psi. Not more than 2 test cylindersmay have a strength of less than 1,150 psi.

If compressive strength tests performed in the field show that the concrete has attained the specifiedaverage strength, you may open the lane to traffic at the age of break. Perform the compressive strengthtests under the specifications for sampling and testing cylinders in section 90-1.01D(5)(a). If you chooseto use this option, notify the Engineer before starting construction.

51-1.01D(3) Test PanelsTest panels must be:

1. Constructed at an authorized location2. At least 4 by 4 feet by 5 inches deep3. Constructed and finished using the personnel, materials, equipment, and methods to be used in the

work4. Authorized before starting work

The Engineer may request that additional test panels be constructed until the specified finish, texture, andcolor are attained.

The Engineer uses the authorized test panel to determine acceptability of the work.

51-1.01D(4) Testing Roadway Surfaces51-1.01D(4)(a) GeneralThe Engineer tests roadway surfaces for smoothness, coefficient of friction, and crack intensity.

51-1.01D(4)(b) Surface SmoothnessThe Engineer tests the surface smoothness of the following:

1. Completed roadway surfaces of structures and approach slabs and the adjacent 50 feet of approachpavement


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2. Surfaces of concrete decks to be covered with another material

You must schedule smoothness testing. Allow 10 days for the Engineer to perform smoothness testing.

Before the testing, clean the test area and remove obstructions.

Surface smoothness is tested using a bridge profilograph under California Test 547. Two profiles areobtained in each lane approximately 3 feet from the lane lines and 1 profile is obtained in each shoulderapproximately 3 feet from the curb or rail face. Profiles are taken parallel to the direction of traffic.

Deck surfaces must comply with the following smoothness requirements:

1. Profile trace having no high points over 0.02 foot2. Profile count of 5 or less in any 100-foot section for portions within the traveled way3. Surface not varying more than 0.02 foot from the lower edge of a 12-foot-long straightedge placed

transversely to traffic

Grind surfaces not complying with the smoothness requirements under section 42-3 of the StandardSpecifications until the required smoothness is attained. Grinding must not reduce the concrete cover onreinforcing steel to less than 1-1/2 inches.

Replace portions of decks that cannot be corrected by grinding.

51-1.01D(4)(c) Coefficient of FrictionAfter deck surfaces and approach slabs have been textured, the Engineer tests the coefficient of frictionof the concrete surfaces under California Test 342.

If portions of completed deck surfaces or approach slabs have a coefficient of friction of less than 0.35,those portions must be ground to produce a coefficient of friction of not less than 0.35 or grooved parallelto the center line. Grinding and grooving must comply with section 42 of the Standard Specifications.

51-1.01D(4)(d) Crack IntensityThe Engineer measures crack intensity of deck surfaces after curing, before prestressing, and beforefalsework release. Clean the surface for the Engineer to measure surface crack intensity.

In any 500 sq ft portion of a new deck surface, if there are more than 50 feet of cracks having a width atany point of over 0.02 inch, treat the deck with methacrylate resin under section 15-5.05. Treat the entiredeck width between barriers to 5 feet beyond where the furthest continuous crack emanating from the500 sq ft section is 0.02 inch wide. Treat the deck surface before grinding.

51-1.01D(5) Chemical AdhesivesChemical adhesives for bonding dowels must be on the Authorized Material List. The chemical adhesivemust be appropriate for the installation conditions.


51-1.02B ConcreteExcept for minor structures, the cementitious material content per cubic yard of concrete in structures orportions of structures must comply with the content shown in the following table:


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Use Cementitious material content(lb/cu yd)

Deck slabs and slab spans of bridges 675 min, 800 maxRoof sections of exposed top box culverts 675 min, 800 maxPier columns 675 min, 800 maxSeal courses 675 minOther portions of structures 590 min, 800 maxConcrete for PC members 590 min, 925 max

Except for minor structures, the minimum required compressive strength for concrete in structures orportions of structures is the strength described or 3,600 psi at 28 days, whichever is greater.

51-1.02C Bonding MaterialsBonding materials must be magnesium phosphate concrete, modified high-alumina-based concrete, orportland-cement-based concrete.

Magnesium phosphate concrete must be either single component (water activated) or dual component(prepackaged liquid activator).

Modified high-alumina-based concrete and portland-cement-based concrete must be water activated.

Bonding materials must comply with the requirements shown in the following table:

Property Test method RequirementCompressive strength at: California Test 551

3 hours 21 MPa min24 hours 35 MPa min

Flexural strength at 24 hours California Test 551 3.5 MPa minBond strength at 24 hours: California Test 551

Saturated surface dry concrete 2.1 MPa minDry concrete 2.8 MPa min

Water absorption California Test 551 10 percent maxAbrasion resistance at 24 hours California Test 550 25 g maxDrying shrinkage at 4 days ASTM C 596 0.13 percent maxSoluble chlorides by weight California Test 422 0.05 percent maxWater soluble sulfates by weight California Test 417 0.25 percent max

Magnesium phosphate concrete must be formulated for a minimum initial set time of 15 minutes andminimum final set time of 25 minutes at 70 degrees F. Store the materials in a cool, dry environmentbefore use.

The mix water used with water-activated material must comply with section 90-1.02D.

The quantity of water for single-component type or liquid activator for dual-component type to be blendedwith the dry component, must be within the limits recommended by the manufacturer and must be theleast amount required to produce a pourable batter.

If authorized, you may add retarders to magnesium phosphate concrete. The addition of retarders mustcomply with the manufacturer's instructions.

Magnesium phosphate concrete must not be mixed in containers or worked with tools containing zinc,cadmium, aluminum, or copper metals. Modified high alumina based concrete must not be mixed incontainers or worked with tools containing aluminum.

51-1.02D Rapid Strength ConcreteRSC placed in bridge decks must contain at least 675 pounds of cementitious material per cubic yard.


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RSC must have a minimum 28-day compressive strength of 4,000 psi except RSC placed in bridge decksmust have a minimum 28-day compressive strength of 4,500 psi.

51-1.02E Colored ConcreteColor pigments for colored concrete must be of iron oxides complying with ASTM C 979. The dosagemust not exceed 10 percent by weight of cementitious material in the concrete mix design.

When test panels are specified, cementitious materials and aggregates from the same sources used inthe authorized test panel must be used for the colored concrete in the completed work.

51-1.02F MortarMortar must be composed of cement, sand, and water. Materials for mortar must comply with section 90.The proportion of sand to cement measured by volume must be 2 to 1. Mortar must contain only enoughwater to allow placing and packing. Sand particles must be no larger than 1/2 the size of the recess orspace in which the mortar is to be placed.

51-1.02G GroutGrout must consist of portland cement and water, with a water content of at most 4 gallons per 94 poundsof cement.

51-1.02H Miscellaneous MetalMaterials for access opening covers for new structures must comply with section 75-1.03.

51-1.02H Miscellaneous MaterialsPlastic pipe for deck bleeder drains must be schedule 40 PVC complying with ASTM D 1785.

Galvanized wire cloth for deck bleeder drains must be 1/4-inch mesh with 0.047-inch-diameter wire.

51-1.03 CONSTRUCTION51-1.03A GeneralNot Used

51-1.03B Methods and EquipmentVehicles weighing over 1,000 lb are not allowed on any bridge span until the concrete attains acompressive strength of at least 2,400 psi. Vehicles weighing over 4,000 lb are not allowed on any spanuntil the concrete attains a compressive strength of at least 3,250 psi or attains an age of 28 days.

Vehicles exceeding the weight limitations in Veh Code Div 15 that cross bridges as allowed in section 5-1.37B must not make repetitive crossings of any span until the concrete attains an age of 28 days.

Vehicles with a gross weight over 10,000 lb are not allowed on any span of PS concrete structures untilthe prestressing steel for that span is tensioned.

You may precast structural elements not designated as PC members if authorized. If requested, submitshop drawings for proposed PC members. Include construction joint details, foundation bedding, andother requested information.

You may use the slip form method for constructing pier shafts if (1) the results are equal to those obtainedby compliance with these specifications and (2) adequate arrangements are made and carried out forcuring, finishing, and protecting the concrete.

When slip forms are used for pier construction, the line and grade furnished by the Engineer is limited toestablishing control points and checks of slip form position. You must provide targets, markers, or otherdevices for the Engineer to determine the pier shaft position.

Shotcrete is not allowed as an alternative construction method for reinforced concrete members.

You may construct warped portions of wingwalls at the ends of culverts using shotcrete complying withsection 53-1 of the Standard Specifications.


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51-1.03C Preparation51-1.03C(1) GeneralBottom of footing elevations shown are approximate.

The Engineer may order changes in footing dimensions or elevations.

Where a roughened concrete surface is described, roughen the existing concrete surface by abrasiveblasting, water blasting, or using mechanical equipment.

Pump water from the interior of foundation enclosures without removing concrete materials. Do not pumpwater during concrete placement or for 24 hours after placing concrete, unless the pumping is done froma sump separated from the concrete work.

51-1.03C(2) Forms51-1.03C(2)(a) GeneralForms must be:

1. Mortar tight2. True to the dimensions, lines, and grades of the structure3. Strong enough to prevent deflection during concrete placement

Face exposed surfaces of concrete structures with form panels.

Form panels for exposed surfaces must be plywood complying with or exceeding the requirements ofU.S. Product Standard PS 1 for Exterior B-B (Concrete Form) Class I Plywood or any material thatproduces a similarly smooth, uniform surface. For exposed surfaces, use only form panels in goodcondition and free of defects such as scars, dents, or delaminations.

Design and construct forms for exposed surfaces such that surfaces do not undulate more than 3/32 inchor 1/270 of the center-to-center distance between studs, joists, form stiffeners, form fasteners, or wales inany direction. Stop using forms or forming systems that produce excessive undulations until modificationssatisfactory to the Engineer are made. The Engineer may reject portions of structures with excessiveundulations.

Form exposed surfaces of each element of a concrete structure with the same forming material or withmaterials that produce similar surface textures, color, and appearance.

Use form panels in uniform widths of at least 3 feet and uniform lengths of at least 6 feet except at theends of continuously formed surfaces where the final panel length is less than 6 feet. For members lessthan 3 feet wide, form panels must be the width of the entire member.

Arrange form panels in symmetrical patterns conforming to the general lines of the structure. Placepanels for vertical surfaces with the long dimension horizontal and horizontal joints level and continuous.

Form panels for curved column surfaces must be continuous for at least 1/4 of the circumference or 6feet. For walls with sloping footings that do not abut other walls, you may place panels with the longdimension parallel to the footing.

Align form panels on each side of panel joints with supports or fasteners common to both panels so that acontinuous, unbroken concrete plane results. Form filler panels that join prefabricated panels must (1)have a uniform width of at least 1 foot and (2) produce a smooth, uniform surface with consistentlongitudinal joint lines between panels.

Construct forms for exposed surfaces with triangular fillets at least 3/4 by 3/4 inch. Attach fillets so as toprevent mortar runs and to produce smooth, straight chamfers at all sharp edges of the concrete.

Clean inside form surfaces of dirt, mortar, and foreign material. Thoroughly coat forms to be removed withform oil before placing concrete. Form oil must:

1. Be commercial quality or an equivalent coating


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2. Allow the ready release of forms3. Not discolor the concrete

Do not place concrete in forms until:

1. All form construction work has been completed, including removing foreign material2. All materials to be embedded in the concrete have been placed3. Engineer has inspected the forms

Forms for concrete surfaces that will not be completely enclosed or hidden below the permanent groundsurface must comply with the specifications for forms for exposed surfaces. Interior surfaces ofunderground drainage structures are considered completely enclosed surfaces.

Use form fasteners to prevent form spreading during concrete placement. Do not use twisted wire ties tohold forms in position.

Form fasteners and anchors must be of those types that can be removed as specified for form bolts insection 51-1.03F(2) without chipping, spalling, heating or otherwise damaging the concrete surface.

You may cast anchor devices into the concrete for supporting forms or lifting PC members. Do not usedriven types of anchorages for fastening forms or form supports to concrete except for interior surfaces ofgirders in PS box girder bridges where:

1. Girders have more than 2 inches of cover over the reinforcement2. Anchorages do not penetrate the girder more than 2 inches and have a minimum spacing of 6 inches3. Anchorages are placed at least 3 inches clear from the edge of concrete

51-1.03C(2)(b) Removing FormsRemove all forms, except soffit forms for deck slabs of CIP box girders, forms for the interior voids of PCmembers, and the forms in hollow abutments or piers may remain in place for any of the followingconditions:

1. Permanent access into the cells or voids is not shown2. Utility facilities are not to be installed in the completed cells or voids3. Utility facilities to be installed in completed cells or voids are to be inserted into casings that are

placed before the completion of the cell or void4. Permanent access is shown or utility facilities other than those in preplaced casings are to be

installed in cells or voids, and you:4.1 Remove the portions of the forms that obstruct access openings or conflict with utility facilities.4.2 Provide a longitudinal crawl space at least 3 feet high and 2 feet wide throughout the length of

these cells or voids4.3 Use a forming system that leaves no sharp projections into the cells or voids4.4 Remove forms between the hinge and 5 feet past the access openings in cells of CIP box

girder bridges with access openings near the hinges

Clear the inside of the cells or voids of all loose material before completing the forming for the deck of CIPbox girders or for the cells or voids of other members when the forms are to remain in place, or after theremoval of the forms or portions of forms.

You may remove forms that do not support the dead load of concrete if 24 hours have elapsed afterconcrete placement and the concrete has sufficient strength to prevent damage to the surface.

You may remove forms for railings or barriers after the concrete has hardened. Protect exposed surfacesfrom damage.

51-1.03C(2)(c) Permanent Steel Deck Forms51-1.03C(2)(c)(i) GeneralPermanent steel deck forms and supports must comply with ASTM A 653/A 653M, Designation SS,Grades 33 through 80, coating designation G165.


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51-1.03C(2)(c)(ii) Design RequirementsDesign permanent steel deck forms based on the combined dead load of forms, reinforcement, andplastic concrete with an allowance for construction loads of at least 50 psf. The combined dead load mustbe assumed to be at least 160 pcf for normal concrete and 130 pcf for lightweight concrete.

Configure forms such that the weight of deck slab and forms is at most 110 percent of the weight of thedeck slab as shown.

Compute physical design properties under "Design of Cold-Formed Steel Structural Members" of theAISC Steel Manual.

The design span for form sheets is the clear span of the form plus 2 inches, measured parallel to the formflutes.

Maximum allowable stresses and deflections are as follows:

1. Tensile stress must not exceed the lesser of 0.725 times the specified yield strength or 36,000 psi.2. Dead load deflection must not exceed the lesser of 0.0056 times the form span or 1/2 inch. The dead

load for deflection calculations must be at least 120 psf total.3. You may use form camber based on the actual dead load condition. Do not use camber to

compensate for deflection exceeding the allowable limits.

51-1.03C(2)(c)(iii) InstallationDo not weld steel deck forms to flanges of steel girders.

Permanent steel deck forms must not interfere with movement at deck expansion joints.

Clearance between deck forms and bar reinforcement must be at least 1 inch.

Do not use permanent steel deck forms for sections of deck slabs with longitudinal expansion jointsunless additional supports are placed under the joint.

Do not rest form sheets directly on top of girder flanges. Fasten sheets securely to form supports. Provideat least 1 inch of bearing at each end. Place form supports in direct contact with girder flanges. Attachsupports using bolts, clips, or other authorized means.

Locate transverse deck construction joints at the bottom of flutes. Field drill 1/4-inch weep holes at notless than 12 inches on center along the joint line.

Repair galvanized form surfaces damaged before installation by wire brushing to remove loose andcracked coating and applying 2 coats of zinc-rich primer. Do not use aerosol cans. You do not need torepair minor heat discoloration in welded areas.

51-1.03D Placing Concrete51-1.03D(1) GeneralThoroughly moisten forms and subgrade with water immediately before placing concrete.

Place and consolidate concrete using methods that (1) do not cause segregation of the aggregate and (2)produce dense, homogeneous concrete without voids or rock pockets.

Place concrete while fresh and before initial set. Do not retemper partially hardened concrete withadditional water.

Place concrete continuously in each integral part of the structure. Do not start work unless placement canbe completed uninterrupted.

Place concrete for girder spans in at least 2 operations. The last operation must consist of placing thedeck slab. Allow at least 5 days between operations.

Place concrete as close to its final position as possible. Do not use vibrators for extensive shifting ofconcrete.


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Except for CIP piles, do not allow fresh concrete to fall more than 8 feet without using pipes, tubes, ordouble belting to prevent segregation. Do not use double belting unless the member thickness is lessthan 16 inches.

Consolidate concrete using high-frequency vibrators within 15 minutes of placement. Do not use vibratorsfor pipe culvert headwalls and endwalls, slope paving and aprons, and concrete placed under water. Donot attach vibrators to or hold them against forms or reinforcing steel. Do not displace reinforcement,ducts, or prestressing steel during vibrating.

For structure footings over 2.5 feet in depth that have a top layer of reinforcement, reconsolidate theconcrete to a depth of 1 foot after placing, consolidating, and initial screeding of the concrete.Reconsolidate the concrete as late as the concrete will respond again to vibration but not less than 15minutes after the initial screeding.

Vibrators used for concrete with epoxy-coated reinforcement or prestressing steel must have a resilientcovering to prevent damage to the epoxy coating.

You may use external vibrators only if consolidation by other means is not possible. Forms must besufficiently rigid to resist displacement or damage. The use of external vibrators must be authorized.

Do not place concrete for horizontal members until the concrete in supporting vertical members has beenconsolidated and settlement due to bleeding is complete.

Where shown, apply a bond breaker to joint surfaces.

Do not construct drainage structures to final grade until adjacent paving or surfacing is complete.

51-1.03D(2) Concrete Bridge DecksFor concrete decks placed on continuous steel girders or PC concrete girders, place the portion of deckover the supports last.

For decks on PC concrete girders, place intermediate and end diaphragms at least 5 days before placingthe deck concrete.

For decks on structural steel, install cross frames the entire width of the bridge before placing the deckconcrete.

Deck closure pours must comply with the following:

1. During primary deck placement and for at least 24 hours after completing the deck placement,reinforcing steel protruding into the closure space must be free from any connection to reinforcingsteel, concrete, forms, or other attachments of the adjacent structure.

2. Closure pour forms must be supported from the superstructure on both sides of the closure space.

51-1.03D(3) Concrete Placed Under WaterOnly seal course concrete may be placed under water.

If the Engineer determines that it is impossible or inadvisable to dewater excavations before placingconcrete, place a seal course under the water using a tremie or a concrete pump. The seal course mustbe at least 2 feet thick and thick enough to seal the cofferdam.

The tremie must be a watertight tube at least 10 inches in diameter with a hopper at the top. Whenconcrete is deposited into the hopper, flow is induced by raising the discharge end. Equip discharge andtremie tubes with a device to prevent water from entering the tube when charging the tube with concrete.Support the tubes so as to allow for free movement of the discharge end over the entire work surface andrapid lowering of the tube.

Fill the tubes using a method that prevents washing of the concrete. Keep the discharge end submergedin the concrete at all times. The tube must contain enough concrete to prevent water entry.


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Place the concrete carefully in a compact mass. Concrete flow must be continuous until completion of theseal course. The seal course must be monolithic and homogeneous. Do not disturb concrete afterplacement. Maintain still water at the point of placement.

Cure the seal course concrete for at least 5 days before dewatering the cofferdam. Increase the curingtime for seal course concrete placed in water that is below 45 degrees F. Periods of time when the watertemperature is continuously below 38 degrees F is not considered as curing time.

Dewater the cofferdam after the seal course has adequate strength to resist the hydrostatic load. Afterdewatering, clean the top of the concrete of all scum, laitance, and sediment. Remove local high spots toprovide the specified clearance for reinforcing steel before placing fresh concrete.

51-1.03D(4) Construction JointsPlace construction joints only where described unless authorized.

At horizontal construction joints:

1. Thoroughly consolidate fresh concrete surfaces without completely removing surface irregularities2. At joints between girder stems and decks, remove surface laitance, curing compound, and other

foreign materials

Clean construction joint surfaces before placing fresh concrete against the joint surfaces. Removesurface laitance, curing compound, and other foreign materials.

Flush construction joint surfaces with water and allow the surfaces to dry to a surface-dry conditionimmediately before placing concrete.

If authorized in an emergency, you may place a construction joint at a location not described. TheEngineer determines the location of the construction joint and the quantity of additional reinforcing steel tobe placed across the joint.

Locate longitudinal construction joints in bridge decks along lane lines if a joint location is not shown.

51-1.03D(5) Colored ConcreteWhen placing colored concrete:

1. Monitor the water content, weight of cementitious materials, and size, weight, and color of aggregateto maintain consistency and accuracy of the mixed colored concrete.

2. Schedule delivery of concrete to provide consistent mix times from batching until discharge. Do notadd water after a portion of the batch has been discharged.

3. Use consistent finishing practices to ensure uniformity of texture and color.4. Protect surrounding exposed surfaces during placement, finishing, and curing activities of colored

concrete.

If more than 1 concrete pump is used to place concrete, designate the pumps to receive coloredconcrete. The designated pumps must receive only colored concrete throughout the concrete placementoperation.

Cure colored concrete by the forms-in-place method or the curing compound method.

If the curing compound method is used, the curing compound must be clear or match the color of thecolored concrete and must be manufactured specifically for colored concrete. Do not use curingcompounds containing calcium chloride. The time between completing surface finishing and applying thecuring compound must be the same for each colored concrete component.

51-1.03D(6) Bearing SurfacesFor elastomeric bearing pads, wood float finish the concrete bearing surface to a level plane that varies atmost 1/16 inch from a straightedge placed in any direction and is within 1/8 inch of the specified elevation.The bearing area must extend at least 1 inch beyond the limits of the bearing pads.


REVISION 0


For bearing assemblies or masonry plates not embedded in concrete, construct the concrete bearing areaabove grade and grind to a true level plane that (1) does not vary perceptibly from a straightedge placedin any direction and (2) is within 1/8 inch of the elevation shown.

51-1.03E Miscellaneous Construction51-1.03E(1) GeneralWhere shown, paint the bridge name, bridge number, and bent number in neat, 2-1/2-inch-high blackletters and figures.

Where shown and before backfilling to within 3 feet of finished grade, install temporary bumpers at theends of bridges and grade top culverts.

Where pipes outside the structure join the structure, cast bell recesses in the concrete to receive the pipeor cast sections of the pipe in the concrete. If bell recesses are used, mortar the pipe end into the bell.

51-1.03E(2) Placing MortarPlace mortar in recesses and holes, on surfaces, under structural members, and at other locations wheredescribed.

Clean concrete areas to be in contact with mortar of loose or foreign material that would prevent bondingbetween the mortar and the concrete surfaces. Flush the concrete areas with water and allow them to dryto a surface-dry condition immediately before placing the mortar.

Tightly pack mortar to completely fill spaces. Locations where mortar can escape must be mortar-tightbefore placing mortar. Cure mortar for 3 days using the water method under section 90-1.03B.

Do not load mortar until 72 hours after placement unless authorized.

51-1.03E(3) Drill and Bond DowelsFor drill and bond dowels, drill the holes without damaging the adjacent concrete. Holes for bondeddowels must be 1/2 inch larger than the nominal dowel diameter.

If reinforcement is encountered during drilling before the specified depth is attained, notify the Engineer.Unless coring through the reinforcement is authorized, drill a new hole adjacent to the rejected hole to thedepth shown.

Coat the surface of any dowel coated with zinc or cadmium with a colored lacquer. Allow the lacquer todry thoroughly before installing the dowel.

Each drilled hole must be clean and dry when placing the bonding material and dowel. The bondingmaterial and dowel must completely fill the drilled hole. The surface temperature must be at least 40degrees F when magnesium phosphate concrete is placed.

Thoroughly dry finishing tools cleaned with water before working magnesium phosphate concrete.

Leave dowels undisturbed for 3 hours or until the dowels can be supported by the concrete.

Cure modified high-alumina-based concrete and portland-cement-based concrete using the curingcompound method. Do not cure magnesium phosphate concrete.

Replace dowels that fail to bond or are damaged.

51-1.03E(4) Drill and Grout DowelsDrill the holes under section 51-1.03E(3).

For drill and grout dowels, drill the holes 1/4 inch larger than the nominal dowel diameter. Immediatelybefore placing dowels, holes must be cleaned, be thoroughly saturated with water, have all free waterremoved, and be dried to a saturated surface dry condition.


REVISION 0


Place grout into the holes and insert the dowels. Retempering of grout is not allowed. Cure grout at least3 days or until the dowels are encased in concrete. Immobilize the dowels during the curing period. Cureusing curing compound method or by keeping the surface continuously damp.

Replace dowels that fail to bond or are damaged.

51-1.03E(5) Drill and Bond Dowels (Chemical Adhesive)For drill and bond dowel (chemical adhesive), the drilled hole diameter and depth must comply with theICC evaluation report for the size of dowel being installed unless otherwise shown. Increase the drilledhole depth specified in the ICC evaluation report by 50 percent when dowels are epoxy coated.

Immediately after inserting the dowels into the chemical adhesive, support the dowels as necessary toprevent movement until the epoxy has cured the minimum time specified in the Authorized Material List.

Replace dowels that fail to bond or are damaged. Drill new holes adjacent to rejected dowels and installreplacement dowels.

Drill the holes without damaging the adjacent concrete. If reinforcement is encountered during drillingbefore the specified depth is attained, notify the Engineer. Unless coring through the reinforcement isauthorized, drill a new hole adjacent to the rejected hole to the depth shown.

51-1.03E(6) Nonskid Abrasive FinishWhere shown, place a nonskid abrasive finish on pedestrian walkways, stair treads, and landings. Thenonskid finish must consist of commercial-quality aluminum oxide, silicon carbide, or almandite garnet gritparticles, sieve size no. 12 to 30 or no. 14 to 35. Uniformly apply grit particles at a rate of at least 0.3 lb/sqft onto the floated concrete surface while the concrete is plastic. Bury the particles into the concrete to adepth of approximately 0.7 times the diameter of each particle.

51-1.03E(7) Drains in WallsWhere shown, construct drain holes and weep holes in abutment walls, wingwalls, and retaining walls.Cover retaining wall and abutment wall drains at the back face of the wall with 1/4-inch mesh, 0.025-inch-diameter aluminum or galvanized steel wire hardware cloth. Mount hardware cloth in forms beforepouring concrete or fasten the cloth to the exterior concrete surface with masonry nails.

In addition to wall drains, install hydrostatic pressure relief holes 3 inches in diameter at the bottom ofwalls immediately above footings at approximately 15-foot centers.

51-1.03E(8) Deck Bleeder DrainsThe Engineer provides the exact location for each deck bleeder drain.

Drill the holes for drains in existing bridges using a diamond core drill bit. Do not spall hole edges. Holesmust be 2 inches in diameter.

Install drains such that the top of the pipe is approximately 1/4 inch below the concrete deck surface.Replace drains out of position as determined by the Engineer.

Secure plastic pipe installed in existing bridges with an epoxy adhesive. Score the outside surfaces of thepipe before installing the pipe. Spread epoxy on both the pipe and hole surfaces. Epoxy must completelyfill the space between the pipe and the hole.

Install drains before placing the deck seal. Center the wire cloth above the drains. Place the cloth afterplacing the deck seal and before placing the HMA. Secure the cloth using an authorized method toprevent movement during HMA placement. Do not damage the deck seal.

51-1.03E(9) Utility FacilitiesWhere shown, utility facilities will be carried in or on structures.

Install hangers, anchor bolt inserts, manhole frames and covers, sleeves, and other accessories requiredfor the utility facility that must be cast in the concrete. The utility owner will furnish these items.


REVISION 0


The utility owner will furnish and install conductors and casings when the structure is ready for theinstallation and before any work that interferes with installation is started.

Notify the Engineer at least 30 days before the date structures are ready for utility installation. TheEngineer will notify the utility owner.

51-1.03E(10) Concrete Headers and Steel PlatesConcrete for concrete headers must comply with the specifications for minor concrete.

Steel plates and attachment hardware must comply with section 75 except that galvanizing is notrequired.

51-1.03E(11) Pier ColumnsPlace concrete for pier columns against firm, undisturbed foundation material on the bottom and sides ofthe pier column excavations except place concrete against forms where shown. Immediately beforeplacing concrete, all excavated surfaces against which the concrete is to be placed must be free fromstanding water, mud, debris, and loose material.

51-1.03E(12) Diaphragm BolstersNot Used

51-1.03E(13) Hinge TiedownsInstall temporary hinge tiedowns and anchorages (1) within 10 days of completing longitudinalprestressing and (2) before releasing bridge falsework in the hinge span and adjoining span.

Hinge tiedowns shown in the following table must be left in place and will become the property of theDepartment:

Bridge name and no. Hinge in span no.

Submit shop drawings and calculations for installing hinge tiedowns. Shop drawings and calculationsmust be sealed and signed by an engineer who is registered as a civil engineer in the State. Include inthe submittal:

1. Details of procedures and methods for tensioning and detensioning of the hinge tiedowns2. Additional concrete and reinforcement required for the hinge tiedowns3. Rearrangement of reinforcement, prestressing, and other materials to accommodate the hinge

tiedowns4. Required strengthening of bridge components and foundations for hinge tiedown forces

Construct hinge tiedowns and anchorages using suitable materials that do not yield during extendedsustained loadings. The hinge tiedowns must allow for:

1. Checking and simple adjustment of the force during their service life using commonly availableequipment and tools

2. Easy and gradual detensioning, simple removal and a minimal amount of repair to the bridge surfacesafter removal

Case the hinge tiedowns for a height of 10 feet above the ground with plastic or steel pipe secured withvandal-resistant retaining devices. Cover and protect anchorages from vandalism.

Protect exposed metal from corrosion using methods that are at least equivalent to cleaning and paintingwith inorganic zinc-rich primer.

Hinge tiedowns must (1) provide the minimum clearances shown and (2) not impair the structural integrityof the bridge or bridge foundations.


REVISION 0


Do not attach hinge tiedowns to bridge columns unless shown.

Stress the tiedown elements under section 50-1.03B.

Tension the hinge tiedowns after prestressing concrete and before releasing falsework in the supportinghinge span and adjoining span. The tension force must be as shown.

Distribute the hinge tension force to at least 2 tiedowns of approximately equal force, placedsymmetrically about the bridge centerline. Apply at most 1/2 of the tension force to a tiedown beforeapplying an equal force to the adjacent tiedowns. Do not apply more than 1/6 of the tension force for theentire hinge eccentrically about the bridge centerline at any time.

Maintain full tension in the hinge tiedowns during the Contract. Immediately before Contract acceptance,check the tension in the hinge tiedowns and adjust them to provide the tension force shown.

Remove existing hinge tiedowns at the locations shown in the following table:

Bridge name and no. Hinge in span no.

Hinge tiedowns must remain fully tensioned during the construction of the supported span in the adjoiningframe.

Except for concrete above the bridge deck, all the concrete at the hinge must be in place at least 10 daysbefore detensioning any tiedowns to be removed. Gradually detension and remove hinge tiedowns beforereleasing the superstructure falsework in the supported span.

Detension tiedowns incrementally. Release at most 1/2 of the total force in a tiedown before releasing anequal force at adjacent tiedowns. Do not apply more than 1/6 of the tension force for the entire hingeeccentrically about the bridge centerline at any time. Detension wires, strands, or bars before cutting orremoving them.

After removing tiedowns, fill remaining blockouts and recesses with concrete. Finish surfaces to matchthe surrounding surfaces. Removal of embedded fasteners and metal parts must comply with thespecifications for removing form bolts in section 51-1.03F(2). Remove buried portions of tiedowns andanchorages to 3 feet below finished grade except that limits for removal must comply with thespecifications for embedded fasteners and metal parts if tiedowns or anchorages are attached to bridgefootings or other buried structures.

51-1.03F Finishing Concrete51-1.03F(1) GeneralStrike off exposed surfaces of consolidated concrete to the lines and grades shown. Provide a uniformsurface texture having the specified finish without undulations or irregularities.

The Engineer determines the acceptability of the surface finishes.

51-1.03F(2) Ordinary Surface FinishApply ordinary surface finish to all concrete surfaces as a final finish or before applying a higher classfinish.

Ordinary surface finish includes:

1. Filling holes or depressions2. Repairing rock pockets and unsound concrete3. Removing fins and projections flush to the surface4. Removing stains and discolorations visible from traveled ways

You do not need to remove fins from surfaces that are buried underground or enclosed.


REVISION 0


Ordinary surface finish must be the final finish for the following surfaces:

1. Undersurfaces of slab spans, box girders, spandrel arch spans, and floor slabs between girders ofsuperstructures

2. Inside vertical surfaces of T girders of superstructures3. Surfaces to be buried underground or covered with embankment and surfaces of culverts above

finished ground that are not visible from the traveled way

Remove form bolts and metal placed for your convenience to at least 1 inch below the concrete surface.Clean and fill the resulting holes with mortar. You do not need to remove form bolts in box girder cellsexcept you must remove bolts flush if deck forms are removed from the cells.

Fill bolt holes with mortar under section 51-1.03E(2). Fill depressions and pockets with packed mortar orshotcrete as determined by the Engineer. Cure filler under section 51-1.03H.

For exposed surfaces, add enough white cement to the patching material to match the surroundingconcrete after drying.

If the Engineer determines that rock pockets are extensive, remove and replace the affected portions ofthe structure.

51-1.03F(3) Class 1 Surface FinishClass 1 surface finish includes finishing concrete surfaces to produce smooth, even surfaces of uniformtexture and appearance without bulges, depressions, or other imperfections. Use power carborundumstones or disks to remove bulges and other imperfections.

Do not apply Class 1 surface finish until a uniform appearance can be attained.

Sand areas not complying with the Class 1 surface finish requirements using power sanders or otherauthorized abrasive means until the specified surface finish is attained.

Class 1 surface finish must be the final surface finish for the following surfaces:

1. Except for those surfaces listed in ordinary surface finish, the surfaces of bridge superstructures,including the undersurfaces of deck overhangs

2. Surfaces of bridge piers, piles, columns, and abutments, and retaining walls above finished groundand to at least 1 foot below finished ground

3. Surfaces of open spandrel arch rings, spandrel columns, and abutment towers4. Surfaces of pedestrian undercrossings, except floors and surfaces to be covered with earth5. Surfaces of culvert headwalls above finished ground and endwalls visible from a traveled way6. Interior surfaces of culvert barrels having a height of 4 feet or more for a distance equal to the culvert

height where visible from a traveled way7. Interior surfaces of pump house motor and control rooms and engine-generator rooms8. Surfaces of railings

51-1.03F(4) Class 2 Surface FinishWhere a Class 2 surface finish is described:

1. Apply an ordinary surface finish to the concrete surface.2. Abrasive blast the surface to a rough texture and then thoroughly wash the surface with water.3. Pneumatically apply a mortar coat approximately 1/4 inch thick in at least 2 passes to the damp

surface. The coating must firmly bond to the concrete surface.

The mortar coat must consist of either (1) sand, portland cement, and water, mechanically mixed beforeentering the nozzle or (2) premixed sand and portland cement, with water added before leaving thenozzle. The proportion of cement to sand must be at least 1 to 4. Use sand with a grading suitable for thework.


REVISION 0


You may substitute cementitious material complying with section 90 for portland cement. You may useadmixtures specified in section 90 if authorized.

Do not mortar coat areas where bridge name or other designations are to be painted.

The coating surface must be (1) uniform without unsightly bulges, depressions, or other imperfections and(2) as left by the nozzle. Protect the coating from damage and keep it damp for 3 days after placing.Remove and replace loose areas of coating.

Where a Class 2 surface finish is described for a pedestrian undercrossing, use silica sand and whiteportland cement.

51-1.03F(5) Finishing Roadway Surfaces51-1.03F(5)(a) GeneralConstruct roadway surfaces of structures, approach slabs, sleeper slabs, and adjoining approachpavement, and concrete decks to be covered with another material, to the grade and cross sectionshown. Surfaces must comply with the specified smoothness, surface texture, and surface crackrequirements.

The Engineer sets deck elevation control points for your use in establishing the grade and cross sectionof the deck surface. The grade established by the deck elevation control points includes all camberallowances. Elevation control points will not be closer together than approximately 8 feet longitudinallyand 24 feet transversely to the bridge centerline.

Before starting concrete placement for any deck section:

1. Set to grade all rails and headers used to support or control the finishing equipment2. Check rails and headers to ensure the completed deck complies with smoothness requirements3. Move the finishing equipment over the length of the section to check steel and bulkhead clearances

Deck surfaces and approach slabs must have a uniform surface texture with a coefficient of friction of notless than 0.35 when opened to traffic or before seal coats are placed, whichever occurs first.

Complete the smoothness testing and any required grinding before applying seal coats.

Finish bridge decks to be covered with membrane seals to a smooth surface free of mortar ridges andother projections. The coefficient of friction requirements do not apply for these bridge decks.

Where a future widening is shown, strike off deck surfaces under curbs, railings, barriers, and sidewalksto the same plane as the roadway and leave undisturbed.

51-1.03F(5)(b) Bridge Deck Surface TextureNot Used

51-1.03G Concrete Surface Textures51-1.03G(1) GeneralProvide the concrete surface textures shown. The Engineer determines the acceptability of the surfacetextures.

Fractured rib texture must consist of straight ribs of concrete with a fractured texture on the raised surfacebetween ribs. Grooves between ribs must be (1) continuous with no apparent curves or discontinuitiesand (2) straight to within 1/4 inch in 10 feet. The texture must have random shadow patterns. Brokenconcrete at adjoining ribs and groups of ribs must have a random pattern. The texture must not haverepetitive fractured surfaces or secondary shadow patterns.

Heavy blast texture must consist of an abrasive-blasted concrete surface of uniform color and sandytexture with air and water bubbles in the concrete partially exposed.


REVISION 0


Formed relief texture must consist of a formed relief constructed to the dimensions and shapes shownwith a Class 1 surface finish. Intersecting corners of plane surfaces must be sharp and crisp withouteasing or rounding.

Construct a test panel for each type of concrete surface texture shown.

Cure concrete surface textures by the forms-in-place or water methods.

51-1.03G(2) Form LinersUse form liners for concrete surface textures except for heavy blast and formed relief textures. Otherforming methods must be authorized.

Form liners must (1) be manufactured from an elastomeric material by a manufacturer of commerciallyavailable concrete form liners and (2) leave a crisp, sharp definition of the concrete surface texture.

Form liners must comply with the requirements shown in the following table:

Property Test RequirementShore A hardness ASTM D 2240 50–90Tensile strength ASTM D 412 1,000 psi min

Comply with the form liner manufacturer's instructions for use.

Seal and repair cuts and tears in form liners under the form liner manufacturer's instructions. Do not useform liners that are delaminated or deformed.

Extend form liners the full length of texturing, with transverse joints at 8-foot minimum spacing. Do not usesmall pieces of form liners. Align grooves straight and true. Grooves must match at joints between formliners. For grooved patterns, joints in the direction of grooves must be located in depressions. Buttadjoining liners together without distortion, open cracks, or offsets. Clean joints between liners andremove mortar before use.

Adhesives must be compatible with the form liner material and the concrete. Adhesives must berecommended by the liner manufacturer and not cause swelling of the liner material.

Cast form liner patterns to prevent recurring textural configurations exhibited by repeating, recognizableshadow patterns. Remove surfaces with recurring textural configurations by reworking using authorizedmethods or by replacement.

Use form release agents recommended by the form liner manufacturer. Release agents must not:

1. Cause swelling of the liner material2. Cause delamination from the forms3. Stain the concrete4. React with the liner material

Coat form liners with a thin film of release agent. For textures with longitudinal patterns, apply the releaseagent using a natural bristle brush in the direction of the pattern. Clean excess release agent from linersusing compressed air. Remove release agent buildup due to liner reuse at least every 5 uses.

Form liners must release without leaving pieces of liner on the concrete or removing concrete from thesurface.

Except for formed relief textures, abrasive blast concrete surface textures with fine abrasive afterremoving forms to remove sheen without exposing coarse aggregate.

51-1.03H Curing Concrete StructuresExcept for bridge decks, cure newly placed concrete for CIP structures using the water method or theforms-in-place method under section 90-1.03B.


REVISION 0


Cure the top surface of bridge decks using both the curing compound method and the water method. Thecuring compound must be curing compound no. 1.

Cure the top surface of bridge decks to be sealed with butyl rubber membrane using only the watermethod.

For bridge decks and flat slabs using the water method without a curing medium, keep the entire surfacedamp by applying water with an atomizing nozzle that forms a mist and not a spray until the concrete hasset. After the concrete has set, continuously sprinkle the entire concrete surface with water for at least 7days.

You may use a curing compound complying with section 90-1.03B(3) for the following:

1. Concrete surfaces of construction joints2. Concrete surfaces that are to be buried underground3. Concrete surfaces not visible from a public traveled way, where only a ordinary surface finish is to be

applied and a uniform color is not required

If you use the curing compound method on the bottom slab of box girder spans, the curing compoundmust be curing compound no. 1.

When ordered during periods of hot weather, apply water to concrete surfaces being cured by the curingcompound method or by the forms-in-place method until the Engineer determines that a cooling effect isno longer required.

For RSC using portland cement:

1. Cure the concrete using the curing compound method. Fogging of the surface with water after thecuring compound has been applied is not required.

2. Immediately repair any damage to the film of the curing compound with additional curing compound.Do not repair damage to the curing compound after the concrete is opened to traffic.

3. Cover the surface with an insulating layer or blanket when the ambient temperature is below 65degrees F during the curing period. The insulation layer or blanket must have the R-value ratingshown in the table below. A heating tent may be used instead of or in combination with the insulatinglayer or blanket.

Temperature range duringcuring period (°F)

R-value rating, min

55–65 145–55 239–45 3

51-1.03I Protecting Concrete StructuresMaintain concrete at a temperature of not less than 45 degrees F for 72 hours after placing and at notless than 40 degrees F for an additional 4 days.

51-2 JOINTS51-2.01 GENERAL51-2.01A General51-2.01A(1) SummarySection 51-2.01 includes general specifications for constructing, sealing, and protecting joints in concretestructures.

51-2.01A(2) DefinitionsNot Used


REVISION 0


51-2.01A(3) SubmittalsSubmit a certificate of compliance for polyethylene material for snow plow deflectors.

51-2.01A(4) Quality Control and AssuranceNot Used

51-2.01B Materials51-2.01B(1) GeneralPremolded expansion joint filler must comply with ASTM D 1751.

Expanded polystyrene must be commercially available polystyrene board with (1) a flexural strength of atleast 35 psi when tested under ASTM C 203 and (2) a compressive yield strength from 16 to 40 psi at 5percent compression. Face the surfaces of expanded polystyrene that concrete is placed against with1/8-inch-thick hardboard complying with ANSI A135.4. You may use other facing materials that provideequivalent protection. Secure the hardboard using nails, waterproof adhesive, or other authorized means.

51-2.01B(2) Expansion Joint ArmorFabricate expansion joint armor from steel plates, angles, or other structural shapes under section 75.Shape the armor to the section of the concrete deck and match-mark it in the shop.

51-2.01B(3) Snowplow DeflectorsSnowplow deflectors must consist of ultra-high-molecular-weight polyethylene plates with anchoragedevices.

Anchorage devices must comply with ASTM A 276, type UNS S32205 or S31803.

Ultra-high-molecular-weight polyethylene plates must be UV stabilized and comply with ASTM D 4020and the requirements shown the following table:

Property Test method RequirementDensity ASTM D 792 58 pcf, minTensile strength, ultimate ASTM D 638 5,800 psi, minTensile strength, yield ASTM D 638 2,750 psi, minElongation at break ASTM D 638 290%Hardness ASTM D 2240, Shore D 60 min

Drilling and bonding anchorage devices must comply with the specifications for drilling and bondingdowels in section 51-1.03E(3).

Where shown, apply a thread locking system to the anchorage devices under section 75-1.03.

51-2.01C ConstructionConstruct open joints using a suitable material that you subsequently remove. Do not chip or breakconcrete corners when removing the material. Reinforcement must not extend across an open joint.

For filled joints, place premolded or expanded polystyrene joint filler in position before placing concrete.Fill holes and joints with mastic to prevent the passage of mortar or concrete.

Finish concrete edges at joints using an edger.

Straighten warped sections of expansion joint armor before placing. Use positive methods to holdassemblies in the correct position during concrete placement.


REVISION 0


51-2.02 SEALED JOINTS51-2.02A General51-2.02A(1) General51-2.02A(1)(a) SummarySection 51-2.02 includes specifications for fabricating and installing sealed joints.

Sealed joints must:

1. Be in planned position2. Resist the intrusion of foreign material and water3. Provide bump-free passage of traffic

MR is measured normal to the longitudinal joint axis.

Use the seal type shown in the following table for the MR shown:

Movement rating Seal typeMR 1 inch Type A or B

1 inch < MR 2 inches Type B2 inches < MR 4 inches Strip seal joint seal assembly

MR 4 inches Modular unit joint seal assembly or seismic joint

51-2.02A(1)(b) DefinitionsNot Used

51-2.02A(1)(c) SubmittalsSubmit a work plan for cleaning expansion joints. Include details for preventing material, equipment, ordebris from falling onto traffic or railroad property.

51-2.02A(1)(d) Quality Control and AssuranceNot Used

51-2.02A(2) MaterialsYou may clean and paint metal surfaces of joint seal assemblies instead of galvanizing. Cleaning andpainting must comply with the specifications for new structural steel in section 59-2 except SSPC-QP 1,SSPC-QP 2, and SSPC-QP 3 certifications are not required. Finish coats are not required. Do not paintstainless steel or anchorages embedded in concrete.

51-2.02A(3) ConstructionThe Engineer may order you to install a joint seal larger than required by the MR.

The joint opening at the time of placement must be that shown adjusted for temperature. Do not impairthe joint clearance.

Cover or otherwise protect joints at all times before joint seals are installed. Do not allow debris or foreignmaterial to enter joints.

Clean expansion joints at existing bridges before installing joint seals. Remove all existing seal material,dirt, debris, damaged waterstops, and joint filler. Use methods that do not damage existing soundconcrete.

Verify the joint size after cleaning.

Clean existing joints with undamaged waterstops to the top of the waterstop unless the waterstop is to beremoved.


REVISION 0


Clean existing joints without waterstops and joints with damaged waterstops down to the hinge or bearingseat.

Repair joint damage as ordered.

51-2.02B Type A and AL Joint Seals51-2.02B(1) General51-2.02B(1)(a) SummarySection 51-2.02B includes specifications for installing Type A and AL joints seals.

Type A and AL joint seals consist of field-mixed silicone sealant placed in grooves in the concrete.

51-2.02B(1)(b) DefinitionsNot Used

51-2.02B(1)(c) SubmittalsSubmit a certificate of compliance and certified test report for each batch of sealant.

51-2.02B(1)(d) Quality Control and AssuranceProvide certificates of compliance in accordance with 51-2.02B(1)(c).

51-2.02B(2) MaterialsThe sealant must be a 2-component silicone type that withstands a ±50 percent movement.

The sealant must comply with the requirements shown in the following table:

Property Test method RequirementModulus at 150 percentelongation

California Test 435 8–75 psi

Recovery California Test 435 21/32 inch maxNotch test California Test 435 Notched or loss of bond, 1/4 inch maxWater resistance California Test 435 Notched or loss of bond, 1/4 inch maxUltraviolet exposure California Test 435 No more than slight cracking or checkingCone penetration California Test 435 4.5–12.0 mm

The sealant must be self-leveling and cure rapidly enough to not flow on grades up to 15 percent.

Label sealant containers or provide identification tickets for tanks of 2-component material. Include thefollowing:

1. Material designation2. Lot number3. Manufacturer's name and instructions for use4. Dates of manufacture, packing, and expiration

Do not use material that has expired unless it is retested and authorized.

Polyethylene foam or rod stock for retaining sealant must be commercial quality with a continuous,impervious glazed surface.

51-2.02B(3) Construction51-2.02B(3)(a) GeneralDo not use sealant or adhesive that has skinned over or cannot be redispersed by hand stirring.

Abrasive blast clean joints and remove foreign material with high-pressure air immediately beforeinstalling seals. Protect waterstops during cleaning.


REVISION 0


Joint surfaces must be surface dry when seals are placed.

Place the sealant using equipment that mixes and extrudes the sealant into the joint. The equipment andthe sealant placement must be as recommended by the sealant manufacturer.

Do not use liquid components that have been exposed to air for more than 24 hours.

51-2.02B(3)(b) Type A Seal PreparationFor Type A joint seals, do not start cutting grooves until joint material is delivered to the job site.

Cut grooves in the concrete using saws having diamond blades with at least a 3/16-inch thickness. The1st pass depth for groove sides must be at least 2 inches. The top width must be within 1/8 inch ofspecified width and the bottom width must not vary from the top by more than 1/16 inch for every 2 inchesof depth.

Cutting grooves in existing decks includes cutting conflicting reinforcing steel.

Saw cutting grooves is not required at the following locations:

1. Joints armored with metal2. Joints in curbs, sidewalks, barriers, and railings, if grooves are formed to the required dimensions3. Existing joints where Type A seals are to be installed

Remove all material from the deck joint to the bottom of the saw cut. Remove foreign material from jointsin curbs, sidewalks, barriers, railings, and deck slab overhangs.

The Engineer may order you to saw cut grooves at existing joints to be sealed with a Type A joint seal.Repair spalls, fractures, or voids in the grooved surface at least 64 hours before installing the joint seal.Bevel the lips of saw cuts by grinding.

51-2.02B(3)(c) Type AL Seal PreparationFor Type AL joint seals, remove expanded polystyrene and foreign material to the depth of the joint seal.Grind or edge the lip of the joint.

51-2.02C Type B Joint Seals51-2.02C(1) General51-2.02C(1)(a) SummarySection 51-2.02C includes specifications for installing Type B joint seals.

Type B joint seals consist of preformed elastomeric joint seals placed in grooves in the concrete.

51-2.02C(1)(b) DefinitionsNot Used

51-2.02C(1)(c) SubmittalsSubmit a certificate of compliance with certified test report for each lot of elastomeric joint seal andlubricant-adhesive. Test reports must include the seal MR, the manufacturer's minimum uncompressedwidth, and test results.

Submit joint seal test samples selected by the Engineer for testing with certificates of compliance at least30 days before use.

51-2.02C(1)(d) Quality Control and AssuranceThe Engineer selects test samples of joint seal material and lubricant-adhesive at random from each lot ofmaterial. Test samples are selected from stock at the job site or at a location acceptable to the Engineerand the manufacturer. Joint seal test samples must be at least 3 feet long.

Demonstrate the adequacy of installation procedures for Type B seals before starting installationactivities.


REVISION 0


51-2.02C(2) MaterialsPreformed elastomeric joint seals must:

1. Comply with ASTM D 26282. Consist of a multi-channel, nonporous, homogeneous material furnished in a finished, extruded form3. Have a minimum seal depth at the contact surface of at least 95 percent of the minimum

uncompressed seal width designated by the manufacturer4. Provide a MR of at least that shown when tested under California Test 6735. Have the top and bottom edges in continuous contact with the sides of the groove throughout the

entire range of joint movement6. Be furnished full length for each joint with at most 1 shop splice in any 60-foot length

For seals that would admit water or debris, fill each cell to a depth of 3 inches at the open ends with open-cell polyurethane foam or close the cells by other authorized means.

You may make 1 field splice per joint if authorized. Splice locations and methods must be authorized.Seals must be manufactured full length and then cut at the splice location and rematched before splicing.

Shop and field splices must have no visible offset of exterior surfaces and no evidence of bond failure.

Combination lubricant-adhesive must comply with ASTM D 4070.

51-2.02C(3) ConstructionPrepare joints under section 51-2.02B(3)(b) except remove all material from the deck joint to the top ofthe waterstop or to the depth of the seal to be installed plus 3 inches.

Thoroughly clean contact surfaces and surfaces 1/2 inch from either edge of the groove immediatelybefore applying the lubricant-adhesive. Liberally apply the lubricant-adhesive to vertical groove surfacesand the sides of the joint seal under the manufacturer's instructions.

Install joint seals full length for each joint using equipment that does not distort or damage the seal or theconcrete. The top edges of the installed seal must be in a plane normal to the sides of the groove.

51-2.02D Joint Seal Assemblies with a Movement Rating of 4 inches or Less51-2.02D(1) General51-2.02D(1)(a) SummarySection 51-2.02D includes specifications for fabricating and installing joint seal assemblies with a MR of 4inches or less.

Joint seal assemblies with a MR of 4 inches or less must consist of metal or metal and elastomericassemblies placed in recesses over joints. Strip seal joint seal assemblies consist of a 1 joint cell.

If authorized, you may use an alternative joint seal assembly if:

1. Quality of the alternative assembly and its suitability for the intended application are at least equal tothat of the joint seal assembly shown. The factors to be considered include the ability of the assemblyto resist the intrusion of foreign material and water throughout the full range of movement for theapplication and the ability to function without distress to any component.

2. Alternative joint seal assembly has had at least 1 year of proven satisfactory service under conditionssimilar to those described.

51-2.02D(1)(b) DefinitionsNot Used


REVISION 0


51-2.02D(1)(c) Submittals51-2.02D(1)(c)(i) GeneralFor alternative joint seal assemblies, submit a certificate of compliance for each shipment of joint sealmaterials. The certificate must state that the materials and fabrication involved comply with thespecifications and the data submitted in obtaining the authorization for the alternative joint seal assembly.

51-2.02D(1)(c)(ii) Shop DrawingsFor alternative joint seal assemblies, submit 5 sets of shop drawings for each joint seal assembly to OSD,Documents Unit. Notify the Engineer of your submittal. Include in the notification the date and contents ofthe submittal.

After review, submit 6 to 12 sets, as requested, for final authorization and use during construction. Includedetails of the joint seal assembly and anchorage components, method of installation, blockout details, andadditions or rearrangements of reinforcing steel.

If requested, submit supplemental calculations for each proposed alternative joint seal assembly.

Include in the shop drawings the thermal equation for setting the minimum joint opening at installation.

Shop drawings and calculations must be sealed and signed by an engineer who is registered as a civilengineer.

Allow 25 days for the Department's review.

Submit 1 corrected set to OSD, Documents Unit, for each joint seal assembly within 20 days of finalauthorization.

51-2.02D(1)(d) Quality Control and AssuranceNot Used

51-2.02D(2) Materials51-2.02D(2)(a) GeneralMetal parts must comply with section 75-1.03.

Bolts, nuts, and washers must comply with ASTM A 325.

Sheet neoprene must comply with the specifications for neoprene in section 51-2.04. Fabricate sheetneoprene to fit the joint seal assembly accurately.

51-2.02D(2)(b) Alternative Joint Seal AssembliesAlternative joint seal assemblies must have CIP anchorage components for casting into the deck.

The anchorage components must include anchor studs spaced at a maximum of 4-1/2 inches. The studsmust be at least 5/8 inch in diameter and 8 inches long, except the studs may be 6 inches long in theoverhang.

Instead of complying with section 75-1.03, metal parts may comply with ASTM A 572/A 572M.

Elastomer must be neoprene complying with the requirements shown in Table 1 of ASTM D 2628, exceptrecovery and compression-deflection tests are not required, and the requirements shown in the followingtable:

Property Test method RequirementHardness, Type A durometer ASTM D 2240

(modified)55–70 points

Compression set, 70 hours at100 °C

ASTM D 395(modified)

40 percent max


REVISION 0


The design loading must be the AASHTO LRFD Bridge Design Specifications Design Truck with 100percent dynamic load allowance. The tire contact area must be 10 inches measured normal to thelongitudinal assembly axis by 20 inches wide. The assembly must provide a smooth-riding joint withoutslapping of components or tire rumble.

The MR of the assembly must be measured normal to the longitudinal axis of the assembly. Dimensionsfor positioning the assembly within the MR during installation must be measured normal to thelongitudinal axis. Do not consider skew of the deck expansion joint.

The maximum depth and width of the recess must be such that the primary reinforcement providing thenecessary strength of the structural members is outside the recess. The maximum depth at abutmentsand hinges is 10 inches. The maximum width on each side of the expansion joint is 12 inches.

Horizontal angle points and vertical corners at curbs must be premolded sections or standard sections ofthe assembly that have been miter cut or bent to fit.

51-2.02D(3) ConstructionDeck surfaces must comply with section 51-1.03F(5) before placing and anchoring joint seal assemblies.

Preassemble metal parts of assemblies before installation to verify geometry.

Except for primary reinforcement, continue reinforcement through the recess construction joint into therecess and engage anchorage components of the assembly.

Thoroughly clean joints immediately before installing sheet neoprene. Install sheet neoprene at such timethat it will not be damaged by construction activities.

Place the assembly in the blocked-out recess in the concrete deck surface. The depth and width of therecess must allow the installation of the assembly anchorage components or anchorage bearing surfaceto the lines and grades shown.

For alternative joint seal assemblies, install elastomer under the manufacturer's instructions. Thoroughlyclean the joint and blockout immediately before elastomer installation. Do not damage the installedelastomer during construction activities.

51-2.02D(4) PaymentNot Used

51-2.02E Joint Seal Assemblies with a Movement Rating Over 4 inches51-2.02E(1) General51-2.02E(1)(a) SummarySection 51-2.02E includes specifications for fabricating and installing joint seal assemblies with a MRover 4 inches.

Joint seal assemblies and seismic joints consist of metal or metal and elastomeric assemblies that areanchored or cast into a recess in the concrete over the joint.

Joint seal assemblies must consist of a metal frame system, supporting rails, and support bars withintervening neoprene glands.

Joint seal assemblies will not be authorized without evidence of 1 year of satisfactory service undersimilar conditions.

A qualified representative of the assembly manufacturer must be present during the installation of the 1stassembly and available during remaining installations.

51-2.02E(1)(b) DefinitionsNot Used


REVISION 0


51-2.02E(1)(c) SubmittalsSubmit shop drawings for each joint seal assembly to OSD, Documents Unit. Notify the Engineer of yoursubmittal. Include in the notification the date and contents of the submittal.

After review, submit 6 to 12 sets, as requested, for final authorization and use during construction. Includedetails of the joint seal assembly and anchorage components, method of installation, blockout details, andadditions or rearrangements of reinforcing steel.

If requested, submit supplemental calculations for each proposed alternative joint seal assembly.

Shop drawings and calculations must be sealed and signed by an engineer who is registered as a civilengineer.

Allow 30 days for the Department's review.

Submit 1 corrected set to OSD, Documents Unit, for each joint seal assembly within 20 days ofauthorization.

Submit a certificate of compliance for each shipment of joint seal assembly materials.

51-2.02E(1)(d) Quality Control and AssuranceNot Used

51-2.02E(1)(e) Design RequirementsIf the assembly consists of more than 1 component, design the assembly such that the externalcomponents can be removed and reinstalled at any position within the larger half of the MR to allow forinspection of the internal components.

Except for components in contact with the tires, the design loading must be the AASHTO LRFD BridgeDesign Specifications Design Truck with 100 percent dynamic load allowance. Each component incontact with the tires must support a minimum of 80 percent of the AASHTO LRFD Bridge DesignSpecifications Design Truck with 100 percent dynamic load allowance. The tire contact area must be 10inches measured normal to the longitudinal assembly axis by 20 inches wide. The assembly must providea smooth-riding joint without slapping of components or tire rumble.

The maximum width of unsupported or yielding components or grooves in the roadway surface of theassembly must be 3 inches measured in the direction of vehicular traffic.

The assembly must have CIP anchorage components that form a mechanical connection between thejoint components and the concrete deck.

51-2.02E(2) MaterialsNeoprene glands must comply with the requirements shown in Table 1 of ASTM D 2628, except recoveryand compression-deflection tests are not required, and the requirements shown in the following table:

Property Test method RequirementHardness, Type A durometer ASTM D 2240

(modified)55–70 points

Compression set, 70 hours at100 °C


40 percent max

Metal parts of the joint seal assembly must comply with section 75-1.03 or ASTM A 572/A 572M. Bolts,nuts, and washers must comply with the specifications for HS steel fastener assemblies in section 75-1.02.

Anchorage components must include anchor studs spaced at a maximum of 4-1/2 inches. Studs must beat least 5/8 inch in diameter and 8 inches long, except the studs may be 6 inches long in the overhang.

Assemblies must be assembled at the fabrication site.


REVISION 0


51-2.02E(3) ConstructionMeasure dimensions for positioning the assembly during installation normal to the longitudinal axis of theassembly, disregarding the skew of the deck expansion joint. Assemblies must be capable of adjustmentto the "a" dimension shown.

Deck surfaces must comply with section 51-1.03F(5) before placing joint seal assemblies andanchorages.

The assembly must be completely shop-assembled and placed in a blocked-out recess in the concretedeck surface. The depth and width of the recess must allow the installation of the assembly anchoragecomponents or anchorage bearing surface to the lines and grades shown.

Except for primary reinforcement, continue reinforcement through the recess construction joint into therecess and engage anchorage components of the assembly.

Vertical expansion joints in barriers must be accessible for inspection after recess concrete is placed.

Assemblies must make a watertight, continuous return 6 inches up into barriers at the low side of thedeck. Neoprene glands must be continuous without field splices or joints.

51-2.02F Asphaltic Plug Joint Seals51-2.02F(1) General51-2.02F(1)(a) SummarySection 51-2.02F includes specifications for constructing asphaltic plug joint seals.

Asphaltic plug joint seals consist of an asphaltic binder and aggregate joint seal system.

51-2.02F(1)(b) DefinitionsNot Used

51-2.02F(1)(c) SubmittalsSubmit 5 sets of shop drawings for the proposed asphaltic plug joint seal system to OSD, DocumentsUnit. Notify the Engineer of your submittal. Include in the notification the date and contents of thesubmittal.

Allow 30 days for the Department's review. After review, submit 6 to 12 sets, as requested, for finalauthorization and use during construction.

Submit evidence from the manufacturer that 5,000 linear feet of the joint seal has had at least 2 years ofsatisfactory service under similar conditions.

Submit certificates of compliance for materials used in the joint seals.

Submit a copy of the certified test report for binder material.

51-2.02F(1)(d) Quality Control and AssuranceBinder material must be tested and certified by an authorized laboratory.

A technical representative of the joint seal manufacturer must be present during installation.

51-2.02F(2) MaterialsAll joint components must be from a single manufacturer.

The binder must be a thermoplastic, polymeric-modified asphalt; thermoplastic, polymer-modifiedbitumen; polymer-modified asphalt sealant; or modified elastomeric binder complying with therequirements shown in the following table:


REVISION 0


Property Test method RequirementAsphalt compatibility ASTM D 5329 PassBond, nonimmersed ASTM D 5329 Pass 3 cycles at -20 °F, 50%

Pass 3 cycles at 0 °F, 100%Cone penetration,nonimmersed


1 mm min at 0 ± 2 °F,200 g total weight, 60 seconds

9 mm max at 77 ± 2 °F,150 g total weight, 5 seconds

Ductility ASTM D 113 40 cm min at 77 ± 2 °FFlexibility ASTM D 5329a Pass at 10 ± 2 °FFlow ASTM D 5329 3 mm max at 140 ± 2 °F,

5 hoursResilience ASTM D 5329 40% min at 77 ± 2 °FSoftening point ASTM D 36 180 °F minTensile adhesion ASTM D 5329 550% minSafe heating temperature 390–410 °FRecommended pouringtemperature

360–390 °F

aDo not oven age specimens. After 24 hours at standard conditions, allowspecimens to condition at -10 ± 2 degrees F for 2 hours before testing.

Binder material delivered to the job site must be labeled with:

1. Manufacturer's name2. Lot or batch number3. Dates of manufacturing, packaging, and expiration4. Manufacturer's instructions for use

Binder material must be retested and recertified for use if the expiration date passes.

Aggregates must comply with:

1. Section 90-1.02C except the results of cleanness value and sand equivalent tests must comply withthe requirements for both operating range and contract compliance

2. Asphaltic plug manufacturer's instructions

The polyethylene backer rod must be commercial quality with a continuous, impervious, glazed surfacethat can withstand the hot liquid binder material and is suitable for retaining the hot liquid binder while ithardens.

The bridging plate must be 8 inches wide and at least 1/4 inch thick and comply with ASTM A 36/A 36M.

Cut the bridging plate into 48-inch-minimum-length sections. Place holes for locating pins along thelongitudinal plate centerline 12 inches on center. The locating pins must be at least 16d common steelnails or equal.

51-2.02F(3) ConstructionUniformly double wash and dry natural aggregates before use.

Remove existing expansion dams and asphaltic concrete to the limits shown. Do not damage the deck orremaining asphaltic concrete. Dispose of removed materials.

Steel dowels exposed when removing concrete must be cut off flush with the existing concrete or at thebottom of concrete removal, whichever is lower. Patching around or over dowels in sound concrete is notrequired. Chip voids back to sound concrete and fill voids with magnesium phosphate concrete.

Clean expansion joints under section 51-2.02C(3). Repair spalls when ordered.


REVISION 0


Abrasive blast blockout surfaces to receive the asphaltic plug joint seal.

Clean and dry blockout surfaces and the adjacent 6 inches of roadway immediately before placing thejoint seal. Use a hot air lance producing a minimum temperature of 2,500 degrees F and a directionalvelocity of at least 2,500 feet/second. There must be no moisture present during installation.

Place the top of the backer rod to a depth of at least 1 inch and at most equal to the width of the existinggap below the bottom of the blockout.

Center bridging plate sections over the existing gap. Place the sections flat on the bottom of the blockout.The sections must be butt jointed. Do not overlap the sections or allow gaps between the plate andblockout.

Install the joint seal under the manufacturer's instructions.

51-2.03 SLIDING JOINTSNot Used

51-2.04 WATERSTOPS51-2.04A General51-2.04A(1) SummarySection 51-2.04 includes specifications for installing waterstops.

Waterstops must comply with the cross section and minimum dimensions shown.


51-2.04A(3) SubmittalsSubmit a certificate of compliance for waterstop material stating compliance with paragraph 6 of ArmyCorps of Engineers CRD-C 572.

51-2.04A(4) Quality Control and AssuranceNot Used

51-2.04B MaterialsWaterstops must be manufactured from neoprene or PVC.

Neoprene must (1) be manufactured from a vulcanized elastomeric compound containing neoprene asthe only elastomer and (2) comply with the requirements shown in the following table:

Property Test method RequirementTensile strength ASTM D 412 2,000 psi minUltimate elongation ASTM D 412 300 percent minCompression set,22 hours at 70 °C

ASTM D 395, Method B 30 percent max

Tear strength ASTM D 624, Die C 26 kN/m minHardness, Type A ASTM D 2240 55 ± 5Ozone resistance 20% strain,100 hours at 100 ± 2.2 °F

ASTM D 1149 except 100 ± 20parts per 100,000,000 No cracks

Brittleness temperature at -40 °C ASTM D 746, Procedure B PassFlame propagation ASTM C 542 Must not propagate flameChange in volume, IRM 903,immersed 70 hours at 100 °C

ASTM D 471 80 percent max

Change in mass,immersed 7 days at 70 °C

ASTM D 471 15 percent max


REVISION 0


After accelerated aging under ASTM D 573 for 70 hours at 100 degrees C, the elastomer must not showproperty changes greater than those shown in the following table:

Property RequirementTensile strength -15 percent

Elongation at break -40 percentHardness +10 points

PVC waterstops must (1) be manufactured from PVC complying with CRD-C 572 and (2) comply with theozone resistance requirement for neoprene.

Furnish waterstops full length for straight portions of joints. Manufacturer's shop splices must be fullyvulcanized.

51-2.04C ConstructionUse spacers, wire, or other authorized methods to secure reinforcing bars supporting waterstops.

If waterstops are out of shape or position after placing concrete, remove the concrete and resetwaterstops.

Field splices for neoprene waterstops must be one of the following:

1. Vulcanized2. Mechanical using stainless steel parts3. Made with a splicing union of the same stock as the waterstop

Completed field splices must have a full-size tensile strength of 100 pounds per inch of width.

Field splice PVC waterstops by heat sealing under the manufacturer's instructions. Do not burn the plasticwhen melting.

Cut and splice waterstops at changes in direction as necessary to avoid buckling or distortion of thewaterstop.

51-2.05 STRIP WATERSTOPS51-2.05A GeneralSection 51-2.05 includes specifications for installing strip waterstops.

51-2.05B MaterialsThe neoprene sheet must comply with the specifications for neoprene in section 51-2.04B.

The neoprene adhesive must comply with Federal Specification MMM-A-121.

The protective board must be at least 1/2-inch-thick wood or fiberboard that is at least 4 ft long and thewidth shown.

The neoprene sheet must be smooth and free from pin holes or surface blemishes and show no sign ofdelamination. Surfaces where adhesive is to be applied must have a cloth finish or a buffed finish.Surfaces must be clean and dry when the adhesive is applied.

51-2.05C ConstructionJoin neoprene sheets as follows:

1. Lap the sheets at least 12 inches.2. Apply the adhesive to both faces at the manufacturer's recommended rate.3. Let the adhesive dry to an aggressive tack.4. Bring the sheets together and roll in both directions to obtain a tight bond.


REVISION 0


Abrasive blast clean the concrete surfaces to receive a strip waterstop. Allow the cleaned surfaces to airdry 24 hours before applying the adhesive.

Apply the adhesive to the concrete and neoprene sheet at the manufacturer's recommended rate. Let theadhesive dry to an aggressive tack. Apply the sheet to the concrete surface and roll in both directions toobtain a tight bond.

Completely cover the installed strip waterstops with 1 layer of protective board attached with adhesive.The protective board must remain in place until backfilling is complete.

51-3 BEARINGS51-3.01 GENERALSection 51-3 includes specifications for fabricating and installing bearings.

51-3.02 ELASTOMERIC BEARING PADS51-3.02A General51-3.02A(1) SummarySection 51-3.02 includes specifications for fabricating and installing elastomeric bearing pads.


51-3.02A(3) Submittals51-3.02A(3)(a) GeneralNot Used

51-3.02A(3)(b) Plain Elastomeric Bearing PadsFor plain elastomeric bearing pads, submit:

1. Certificate of compliance with certified test results for the elastomer2. Elastomeric bearing pad test samples at least 30 days before use

51-3.02A(3)(c) Steel-Reinforced Elastomeric Bearing PadsSubmit a certificate of compliance with certified test results from the bearing manufacturer for steel-reinforced elastomeric bearing pads.

Submit 1 test sample from each lot of steel-reinforced bearing pads at least 20 days before use. The sizeof the test sample must be as shown in the following table:

Bearing pad thickness Test sample size2 inches or less Smallest complete bearing shownMore than 2 inches 2.25 ± 0.125-inch-thick test sample at least

8 by 12 inches cut by the manufacturer fromthe center of the thickest complete bearinga

aSubmit the test sample and the remaining parts of the completebearing.

51-3.02A(4) Quality Control and Assurance51-3.02A(4)(a) GeneralNot Used

51-3.02A(4)(b) Plain Elastomeric Bearing PadsFor plain elastomeric bearing pads, the Engineer selects a test sample that is at least 8 by 12 inches fromeach lot of pads or batch of elastomer to be furnished, whichever results in the larger number of testsamples. You may designate that test samples be taken at the point of manufacture or at the job site. Job


REVISION 0


site test samples are completed pads as shown. Furnish additional pads to replace the pads selected fortesting.

The Department takes specimens from the test sample pads, prepares them by cutting and grinding andtests them for tensile strength, elongation, tear strength, and ozone resistance.

51-3.02A(4)(c) Steel-Reinforced Elastomeric Bearing PadsThe Department tests a specimen taken from the test sample steel-reinforced bearing pad underCalifornia Test 663. Specimens must show no loss of bond between the steel and elastomer laminates.

51-3.02B Materials51-3.02B(1) GeneralElastomeric bearing pads 1/2 inch or less in thickness must comply with section 51-3.02B(2).

Elastomeric bearing pads over 1/2 inch in thickness must comply with section 51-3.02B(2) or section 51-3.02B(3).

Silicone grease must comply with Society of Automotive Engineers AS 8660.

Sheet metal must be commercial-quality galvanized sheet steel, smooth and free of kinks, bends, orburrs. Joints must be butt joints sealed with plastic duct-sealing tape.

51-3.02B(2) Plain Elastomeric Bearing PadsFor plain elastomeric bearing pads, pads 1/2 inch or less in thickness must be either laminated or allelastomer. Pads over 1/2 inch in thickness must be laminated. The stacking of individually laminated padsto attain thicknesses over 1/2 inch or the cold bonding of individual laminated pads is not allowed.

Elastomeric bearing pads may be cut from large sheets. Cutting must be performed so as to avoidheating of the material, to produce a smooth edge with no tears or other jagged areas, and to cause aslittle damage to the material as possible.

Neoprene must be the only polymer in the elastomeric compound and must be not less than 60 percentby volume of the total compound. The elastomer must comply with ASTM D 4014, Type CR, Grade 3,with a shear modulus of 110 ± 10 psi.

The elastomer must comply with the requirements shown in the following table:

Property Test method RequirementTensile strength ASTM D 412 2,250 psi minUltimate elongation ASTM D 412 350 percent minCompression set, 22 hoursat 70 °C

ASTM D 395, Method B 25 percent max

Tear strength ASTM D 624, Die C 31.5 kN/m minHardness, Type A ASTM D 2240 with

2 kg mass55 ± 5

Ozone resistance 20%strain, 100 hoursat 40 ± 2 °C

ASTM D 1149except 100 ± 20 parts

per 100,000,000No cracks

Instantaneous thermalstiffening at -40 °C

ASTM D 1043 Not more than 4times the stiffnessmeasured at 23 °C

Low temperaturebrittleness at -40 °C

ASTM D 746, Procedure B

Pass

After accelerated aging under ASTM D 573 for 70 hours at 100 degrees C, the elastomer must not showproperty changes greater than those shown in the following table:


REVISION 0


Property ChangeTensile strength 15 percent lossUltimate elongation 40 percent loss; but not less than 300

percent total elongation of the materialHardness +10 points

51-3.02B(3) Steel-Reinforced Elastomeric Bearing PadsSteel-reinforced elastomeric bearing pads must comply with the specifications for steel-laminatedelastomeric bearings in ASTM D 4014 and the following:

1. Bearing pads must consist of alternating steel laminates and internal elastomer laminates with top,bottom, and side elastomer covers. Steel laminates must have a nominal thickness of 0.075 inch (14gage). Internal elastomer laminates must have a thickness of 1/2 inch. Top and bottom elastomercovers must each have a thickness of 1/4 inch. The combined thickness of internal elastomerlaminates and top and bottom elastomer covers must be equal to the bearing pad thickness shown.The elastomer cover to the steel laminates at the sides of the bearing must be 1/8 inch. If guide pinsor other devices are used to control the side cover over the steel laminates, any exposed portions ofthe steel laminates must be sealed by vulcanized patching.

2. Total bearing thickness must be equal to the sum of the thicknesses of the elastomeric laminates andcovers and the steel laminates.

3. Elastomer must comply with section 51-3.02B(2).

51-3.02C ConstructionNotify the Engineer of the type of bearing pad to be used before constructing the bearing seats. Thebearing seat elevation must correspond to the selected bearing thickness.

Where shown, lubricate the upper surface of the elastomeric bearing pad with a uniform film of siliconegrease before placing the sheet metal cover.

Do not allow grout or concrete seepage into the sliding surface during concrete placement.

51-3.03 PTFE SPHERICAL BEARINGSNot Used

51-3.04 PTFE BEARINGSPTFE bearings, consisting of steel reinforced elastomeric bearing pads, polytetrafluoroethylene (PTFE)surfacing, and stainless steel and steel plates, must comply with the details shown on the plans and theseSpecifications.

Submit working drawings for the PTFE bearings to the Offices of Structure Design, (OSD) for approval.

The manufacturer must furnish Certificates of Compliance for all material used in the PTFE bearings.

The shear modulus of the elastomer in the elastomeric bearing pads must be 110±11 psi.

PTFE sheet must be made from unfilled PTFE resin and must comply with the following requirements:

Test Test Method RequirementsTensile strength

(Minimum)ASTM D 4894 or

D 48952800 psi

Elongation(Minimum)

ASTM D 4894 orD 4895

200 %


REVISION 0


The PTFE resin must be virgin material (not reprocessed) meeting the requirements of ASTMDesignation: D 4894 or D 4895, with a minimum thickness of 1/4 inch. Specific gravity must be from 2.13to 2.19. Melting point must be 623±2°F.

The PTFE sliding surface must be provided with lubricant dimples with a maximum diameter of 0.32-inch,a minimum depth of 0.08-inch, and a maximum depth of one half of the PTFE sheet thickness. Thedimples must be uniformly distributed within the area 1/4 inch from the edges of the PTFE sheet andoccupy between 20 percent and 30 percent of the PTFE sheet area.

Stainless steel plates must comply with the requirements of ASTM Designation: A 240, Type 304, with aminimum thickness of 1/8 inch.

Steel plates, except stainless steel, must comply with the requirements of ASTM Designation: A 709/A709M.

Stud connectors must comply with the provisions in Section 55-1.02, "Materials," of these Specifications.

Welding of structural steel must comply with the requirements of AWS D1.1. Welding of structural steel tostainless steel must comply with the requirements of AWS D1.6.

The PTFE sheet must be adhesive bonded in the recess of steel plate under controlled factory conditions.The adhesive material must be an epoxy resin conforming to the requirements of Federal Specification:MMM-A-134.

Contact surfaces of PTFE sheet and steel plate to be bonded must be uniformly roughened to a minimumroughness height value of 250 microinches.

The side of the PTFE sheet to be bonded must be factory treated by the sodium naphthalene or sodiumammonia process, after the contact surface is roughened.

After completion of the bonding operation the PTFE surface must be smooth and free from bubbles. ThePTFE sheet must show no signs of delamination and must be fully bonded within the recess.

The stainless steel plate must be attached by perimeter welding using Type 309L electrodes. Aftercompletion of the weld operation, the stainless steel plate must be smooth and free from waves.

The flatness of the bearing elements must be controlled such that upon completion of the bearingassembly, the PTFE/stainless steel sliding interface must be in full bearing.

The mating surface of the stainless steel plate with the PTFE surfacing must have a minimum #8 mirrorfinish determined according to ANSI Standard B46.1. The sliding element of the production bearingsmust have a first movement static coefficient of friction not exceeding 0.06 when tested without thecoating of silicone grease.

Steel reinforced elastomeric bearing pads must be fully vulcanized to the steel plates under factorycontrolled conditions, and the bond must have a peel-strength of at least 5.3 newtons per millimeter asdetermined by California Test 663.

Metal surfaces of bearings exposed to the atmosphere and in contact with the structure in the completedwork, except stainless steel surfaces, must be cleaned and painted in conformance with thespecifications for new structural steel in section 59-2 of these Specifications. SSPC-QP 1, SSPC-QP 2,and SSPC-QP 3 certifications are not required.

After installation, the top of the assembly must be removed and a 1/16 inch thick coating of siliconegrease must be applied to the entire PTFE surface and the bearing reassembled without damage to themating sliding surfaces. Silicone grease must comply with the requirements in Military Specification:MIL-S-8660.

Damaged bearings and bearings with scratched mating surfaces must be returned to the factory forreplacement or resurfacing.


REVISION 0


Prior to proof testing or painting, all individual components must be permanently die-stamped on 2 of 4sides with markings consisting of bearing number and contract number. Each bearing must have aunique bearing number and match marks on plate edges to insure correct assembly at the job site.

Full sized PTFE bearings must be proof tested and evaluated for compression and coefficient of initialstatic friction in the presence of the Engineer. The proof tests must be performed on samples randomlyselected by the Engineer from the production bearings to be used in the work. Proof testing must beperformed by the SRJV at the manufacturer's plant or at an approved laboratory. If proof tests cannot beperformed at the specified load, the SRJV must submit to the Engineer for review and approval a testingplan listing additional physical tests. These tests must be performed in the presence of the Engineer, andmust demonstrate that the requirements for proof testing at the specified load are satisfied. The SRJVmust give the Engineer at least 7 days notice before beginning proof testing. Proof testing of PTFEbearings must comply with the following requirements:

A. One bearing per lot of production PTFE bearings must be proof tested. A lot is defined as 25PTFE bearings or fraction thereof of the same type, within a load category.

B. A load category must consist of bearings of differing vertical load capacity within a rangedefined as follows:

1. Bearings with less than or equal to 500 kips maximum vertical load capacity.2. Bearings with greater than 500 kips but less than or equal to 2000 kips maximum

vertical load capacity.3. Bearings with greater than 2000 kips maximum vertical load capacity.

C. Bearings must be proof tested for compression and coefficient of friction.D. Proof tests for compression: The bearing must be held for one hour at 1.5 times the maximum

vertical load shown on the plans for the bearing.E. Proof tests for coefficient of friction: The tests must be performed at the minimum dead load

shown on the plans for the bearing with the test load applied for 12 hours continuously and thetest load must not be reduced or removed prior to friction measurement and the following:

1. The tests must be arranged to allow measurement of the static coefficient of friction onthe first movement of the bearing.

2. The first movement static and dynamic coefficients of friction must be measured at asliding speed not exceeding one inch per minute and must not exceed the specifiedcoefficient of initial static friction.

3. The test bearings must be subjected to a minimum of 100 movements of at least oneinch of relative movement at a sliding speed not exceeding 12 inches per minute.After cycling, the first movement static and dynamic coefficients of friction must bemeasured again at a sliding speed not exceeding one inch per minute and must notexceed the specified coefficient of initial static friction.

F. The bearing surfaces must be cleaned prior to testing.G. Proof testing of bearings must be done after conditioning specimens for 12 hours at 75°±5°F.H. The proof tested bearings must show no visible sign of: (1) bond failure of bearing surfaces,

(2) separation or lift-off of plates from each other or from PTFE surfaces, (3) excessive transferof PTFE to the stainless steel surface, or (4) other defects. When a proof tested bearing failsto comply with these specifications, all bearings in that lot must be individually tested foracceptance.

I. Proof test results must be certified correct and signed by the testing laboratory personnel whoconducted the test and interpreted the test results. Proof test results must include the bearingnumbers of the bearings tested.


REVISION 0


One sample of elastomeric bearing pad, 2.25±0.125" high and not less than 8" x 12" in plan, must be cutby the manufacturer from one of the thickest production elastomeric bearing pads, as directed by theEngineer, and furnished to the Transportation Laboratory.

A test specimen taken from the sample furnished to the Transportation Laboratory will be tested inconformance with the requirements in California Test 663 Part 2Specimens tested must show no loss ofbond between the elastomer and steel laminates.

PTFE bearing sole plates must be temporarily supported during concrete placement. Temporarysupports must prevent the rotation or displacement of the bearings during concrete placing operations.Temporary supports must not inhibit the functioning of the PTFE bearings after concrete is placed.Temporary supports must not restrict the movement at bridge joints due to temperature changes andshortening from prestress forces. Materials for temporary supports within the limits for placing concretemust comply with the requirements for form fasteners.

PTFE and stainless steel surfaces must be protected from contamination and weather damage.

51-4 PRECAST CONCRETE MEMBERS51-4.01 GENERAL51-4.01A SummarySection 51-4 includes specifications for constructing PC concrete members

You may construct PC PS concrete bridge members using segmental construction.


51-4.01C Submittals51-4.01C(1) GeneralSubmit shop drawings for PC concrete members.

51-4.01C(2) GirdersFor PC PS concrete girders, shop drawings must include:

1. Anticipated deflections of the girders before deck placement and the methods of accommodation.Include the following anticipated deflections:1.1 Upward deflection due to prestressing forces1.2 Downward deflection due to girder dead load1.3 Deflection due to creep and shrinkage from the time of girder stressing to the planned deck

placement2. Deflection calculations that consider the age of the girder concrete at the time of stressing and the

planned placement of the deck. Use the concrete producer's estimated modulus of elasticity at theapplicable concrete age for calculating deflections.

Submit a girder erection work plan. Include procedures, details, and sequences for unloading, lifting, anderecting girders and for temporary bracing installation. The work plan must be signed by an engineer whois registered as a civil engineer in the State.

For segmental girder construction, shop drawings must include the following additional information:

1. Details showing construction joints2. Concrete form and casting details3. Arrangement of bar reinforcing steel, prestressing tendons, and pressure-grouting pipe4. Materials and methods for making closures5. Construction joint keys and surface treatment6. Other requested information


REVISION 0


51-4.01C(3) Closure Wall PanelsNot Used

51-4.01C(4) Box CulvertsNot Used

51-4.01D Quality Control and AssurancePC materials must be available to the Department for inspection. Allow the Department free access at alltimes to any portion of the fabrication site where material is stored or work is performed.

PC concrete members are inspected at the fabrication site. Notify the Department when materials aredelivered to the fabrication site. Allow 10 days after notifying the Department before starting fabrication.

The manufacturer of box culverts must sample and test the concrete for compressive strength at leastonce every production shift but not less than once daily. Test result records must be available to theEngineer during regular work shifts.

51-4.02 MATERIALS51-4.02A GeneralPrestressing must comply with section 50.

Reinforcement must comply with section 52.

In a freeze-thaw area, epoxy coat the reinforcement under section 52-2.02.

Bearing plates, threaded inserts, and other metal fittings must comply with section 75-1.03

Concrete for keyways must have a cementitious material content of at least 590 lb/cu yd and a 1-inchmaximum grading. Penetration of the concrete must be near the lower limit of the specified nominalpenetration.

Grout must comply with ASTM C 1107.

Deck shear connector rods, shown as tie rods, must comply with the following:

1. Steel fastener components must comply with section 55.2. Lock washers must be ANSI heavy duty spring washers.3. All metal must be hot-dip galvanized after fabrication under ASTM A123/A123M.

51-4.02B Fabricating Precast Concrete Members51-4.02B(1) GeneralNot Used

51-4.02B(2) Girders, Box Girders, and Double T GirdersBefore curing activities, the top surface of each PC member must be given a coarse texture by broomingwith a stiff bristled broom or by other suitable devices that results in uniform transverse scoring.Additionally, the top surface texture of the following PC members must have at least a 1/4-inch amplitude:

1. Girders2. Box girders with a concrete deck shown3. T girders with a concrete deck shown

Wood float portions of the top surface of box girders to be covered by expanded polystyrene.

For segmental construction, materials for construction joints at exterior girders must match the color andtexture of the adjoining concrete.

51-4.02B(3) SlabsNot Used


REVISION 0


51-4.02B(4) Closure Wall PanelsNot Used

51-4.02B(5) Box CulvertsNot Used

51-4.02B(6) LaggingNot Used

51-4.02B(7) Deck PanelsNot Used

51-4.02C Curing Precast Concrete MembersCure PC concrete members under section 90-4.03.


51-4.03B Girders, Box Girders, and Double T GirdersCarefully handle, store, transport, and erect PC concrete members to avoid twisting, racking, or otherdistortion that would result in cracking or damage to the members.

Handle, store, transport, and erect PC members in an upright position such that the points of support anddirections of the reactions with respect to the member are approximately the same as when the memberis in its final position.

For girders and box girders or double T girders with a concrete deck shown, clean top surfaces of laitanceand curing compound before placing deck concrete.

You may make adjustments to accommodate girder deflections before placing deck concrete, includingadjustments to bearing seat elevations. Adjustments are limited by the following:

1. Minimum permanent vertical clearance under the structure is not reduced.2. Deck profile grade and cross slope cannot be changed.3. Except for box girders, a minimum of 1 inch of deck slab concrete is maintained between the deck

slab reinforcement and the top of the girders.4. For box girders, a minimum of 1 inch of deck slab concrete must be maintained between the top of

expanded polystyrene in the area between the girder webs and the deck slab reinforcement.

Adjustments to accommodate girder deflections are not considered a change in dimensions.

Grout keyways after PC members are in final position. Before grouting, abrasive blast clean the keywaysto expose clean aggregate and flush with water. Allow to dry to a surface dry condition immediatelybefore placing the grout.

Do not place equipment or other loads on spans that have been grouted for at least 72 hours aftergrouting. Do not tension or tighten transverse post-tensioning tendons until 24 hours after grouting thelast keyway.

Except for box girders and double T girders, provide temporary lateral bracing for girders over_____________________. Install bracing at each end of the girder segments and at the midspan.Bracing must be in place before releasing erection equipment and must remain in place until 48 hoursafter concrete diaphragms are placed.

Design temporary bracing to prevent overturning and resist the lateral pressures shown in the followingtable.


REVISION 0


Structure height, H (feet above ground) Lateral pressurea (psf)0 < H 30 15

30 < H 50 2050 < H 100 25

H > 100 30aApply the lateral pressure at the top of the girder in eitherdirection.

51-5 APPROACH SLABS51-5.01 GENERAL51-5.01A SummarySection 51-5 includes specifications for constructing approach slabs and paving notch extensions.

Structure approach drainage systems must comply with section 68-7.


51-5.01C SubmittalsIf using RSC, submit the RSC mix design at least 10 days before constructing the trial slab.

51-5.01D Quality Control and Assurance51-5.01D(1) GeneralIf woven tape fabric is shown, notify the Engineer of the source of woven tape fabric at least 45 daysbefore use.

Notify the Engineer of the type of treated permeable base to be used under approach slabs at least 30days before starting placement. After notification, do not change the type of permeable base withoutauthorization.

51-5.01D(2) Rapid Strength ConcreteBefore starting work on approach slabs constructed using RSC, prepare a trial slab for each concrete mixdesign.

Trial slabs must be:

1. Constructed, finished, and cured within the allowed time with the materials, tools, equipment,personnel, and methods to be used in the work

2. 10 by 20 feet by 9 inches thick3. Constructed near the job site outside the project limits at an authorized location

Trial slabs must demonstrate that you are capable of producing approach slabs within the anticipatedtime periods, including delivery, placement, finishing, and curing times, and under similar atmosphericand temperature conditions expected during construction operations. Multiple trial slabs for each concretemix design may be required to encompass variable atmospheric conditions.

Test the trial slab concrete for compressive strength under section 90-1.01D(5). Trial slab concrete mustdevelop the following minimum compressive strengths:

1. 1,200 psi at the age of break2. 2,500 psi at 3 days3. 4,000 psi at 28 days

51-5.02 MATERIALS51-5.02A GeneralHardboard and expanded polystyrene must comply with section 51-2.01B(1).


REVISION 0


51-5.02B FabricFilter fabric must be Class A.

Woven tape fabric must:

1. Be fabric of woven strips or tapes2. Retain at least 70 percent tensile strength when tested under ASTM D 4355 with 500 hours exposure3. Comply with the requirements shown in the following table:

Property Test method RequirementWeight ASTM D 3776 3 oz/sq yd minGrab breaking load ASTM D 4632 50 lb minApparent elongation ASTM D 4632 35 percent minToughnessa -- 1,200 lb minaPercent apparent elongation times the grab breaking load

51-5.02C ConcreteConcrete for approach slabs and paving notch extensions must contain at least 675 pounds ofcementitious material per cubic yard and comply with one of the following:

1. Cure for at least 5 days before opening to traffic2. Comply with the specifications for RSC

For paving notch extensions, you may use magnesium phosphate concrete, modified high-alumina-basedconcrete, or portland-cement-based concrete, complying with the specifications for bonding materials insection 51-1. The concrete may be extended by using a clean, uniform, rounded aggregate filler with amoisture content of at most 0.5 percent. The quantity of aggregate filler must comply with themanufacturer's instructions. Concrete strengths for the extended concrete must be at least that specifiedfor the bonding materials. The aggregate grading must comply with the requirements shown in thefollowing table:

Sieve size Percentage passing1/2-inch 100No. 16 0–5

In freeze-thaw areas, concrete for approach slabs and paving notch extensions must comply with section90-1.02I.

Concrete for drainage pads must comply with the specifications for minor concrete.

51-5.02D Aggregate BaseAB must be produced from commercial-quality aggregates consisting of broken stone, crushed gravel ornatural rough-surfaced gravel, and sand, in any combination. Grading must comply with the 3/4-inchmaximum grading specified in section 26-1.02B.

51-5.02E Bar ReinforcementBar reinforcing steel must comply with section 52.

In a freeze-thaw area, epoxy coat bar reinforcement under section 52-2.02.

Galvanize unbonded portions of bar reinforcement under section 52-3.

51-5.02F Miscellaneous Joint MaterialsSteel components of abutment ties must comply with section 75-1.03.

PVC conduit used to encase abutment tie rods must be commercial quality.


REVISION 0


Steel angles, plates, and bars at concrete barrier joints must comply with section 75-1.03.

Type AL joint seals must comply with section 51-2.02B.

The pourable seal between the steel angle and concrete barrier must comply with the specifications forType A and AL joint seals in section 51-2.02B.

Sealants may be mixed by hand-held, power-driven agitators and placed by hand methods.

Sliding joints for the sleeper slabs must comply with 51-2.03.

Building paper must be commercial-quality, 30-pound asphalt felt.

51-5.02G Hot Mix AsphaltHMA for a temporary roadway structural section must comply with section 39. Aggregate grading must be3/4-inch HMA Types A or B. Asphalt binder must comply with the specifications for liquid asphalt SC-800in section 93 of the Standard Specifications. The quantity of asphalt binder mixed with aggregate must be0.3 percent less than the OBC as determined under California Test 367.

51-5.03 CONSTRUCTION51-5.03A GeneralDrill and bond bar reinforcement and abutment tie rods under section 51-1.03E(3).

Finish and treat the top surfaces of approach slabs under section 51-1.03F(5). Edger finish the slabedges.

Cure approach slabs using curing compound no. 1.

Abrasive blast clean concrete surfaces and thoroughly clean joints immediately before placing seals. Jointsurfaces must be dry at the time seals are placed.

51-5.03B Type N Approach Slabs51-5.03B(1) GeneralNot Used

51-5.03B(2) Filter FabricPlace filter fabric immediately after grading and compacting the subgrade. Handle and place filter fabricunder the manufacturer's instructions.

Adjacent borders of filter fabric must be overlapped from 12 to 18 inches or stitched. If overlapping theborders, the preceding roll must overlap the following roll in the direction the material is being spread. Ifstitching the border, use yarn of a contrasting color. Yarn size and composition must be as recommendedby the fabric manufacturer. Use 5 to 7 stitches per inch of seam.

Do not operate equipment or vehicles on filter fabric.

51-5.03B(3) Treated Permeable BaseTreated permeable base must be cement treated permeable base.

Construct the treated permeable base under section 29.

Compact CTPB with a vibrating-shoe-type compactor or with a steel-drum roller weighing from 1.5 to 5tons. Compaction must start within 1/2 hour of spreading and must consist of 2 complete coverages of theCTPB.

51-5.03C Type EQ Approach SlabsNot Used


REVISION 0


51-5.03D Type R Approach Slabs51-5.03D(1) GeneralThe Type R approach slab thicknesses shown are minimums. Thicknesses may vary due to materialremoved.

Structure excavation and backfill must comply with section 19-3.

At locations where the removal of existing materials and approach slab construction is not required to becompleted within the same work shift, the requirements for a temporary roadway structural section andtrial slab do not apply.

51-5.03D(2) Removal of Existing FacilitiesRemove portions of existing structures, pavement and base, approach slabs, HMA surfacing, concretepavement, subsealing material, and cement-treated base, as necessary for the construction of the newapproach slab.

Remove portions of seat-type abutments under section 15-4.

Sawcut full depth the outline of concrete pavement to be removed using a power-driven saw. Do not usepower impact tools within 1.5 feet of pavement to remain in place.

Before removing HMA, cut the outlines of excavations in HMA on a neat line to a minimum depth of 0.25foot using a power-driven concrete saw or wheel-type rock-cutting excavator. These excavations must bepermanently or temporarily backfilled to conform to the grade of the adjacent pavement before openingthe lane to traffic.

Dispose of materials no longer used in the work.

51-5.03D(3) Existing Base MaterialUniformly grade and compact the existing base material remaining in place after removing the existingpavement and base materials to the required depth. The finished surface of the base material at any pointmust not extend above the authorized grade.

Fill areas of base material that are low as a result of overexcavation with structure approach slabconcrete at the same time that the new concrete is placed.

Where pavement subsealing has been performed under existing approach slabs, remove the full depth ofsubsealing material. Where removal of CTB is required to construct the approach slab, remove the fulldepth of the CTB.

Fill voids between the new approach slab and the base material remaining in place that are caused byremoval of subsealing material or CTB with either AB or approach slab concrete. If you fill these voidswith structure approach slab concrete, fill the voids at the same time that the new concrete is placed.

51-5.03D(4) Aggregate BaseSpread and compact AB for filling voids below the structure approach slab concrete by methods that willproduce a well-compacted, uniform base, free from pockets of coarse or fine material, to the authorizedgrade. Where the required thickness of AB is 8 inches or less, the base may be spread and compacted in1 layer. Where the required thickness of AB is more than 8 inches, the base must be spread andcompacted in 2 or more layers of approximately equal thickness. The maximum compacted thickness ofany 1 layer must not exceed 8 inches.

51-5.03D(5) Profile GradeEstablish a grade line for the new approach slab that will provide a smooth profile grade. The profilegrade must be authorized.


REVISION 0


51-5.03D(6) Temporary Roadway Structural SectionIf approach slabs cannot be constructed before the lane is opened to traffic, fill the excavation with atemporary roadway structural section. Temporary structural section must consist of a 0.3-foot-thick layerof HMA over AB.

Keep a standby quantity of HMA and AB at the job site for a temporary roadway structural section.

Spread and compact the AB and HMA. Produce a well-compacted, uniform base having a surface ofuniform smoothness, texture, and density, without pockets of coarse or fine material. You may spreadand compact AB and HMA in 1 layer each.

The finished surface (1) must not vary more than 0.05 foot from the lower edge of a 12-foot straightedgeplaced parallel with the centerline and (2) must match the elevation of the existing pavement andstructure along the joints between the existing pavement and structure and the temporary surfacing.

Maintain the temporary structural section until it is replaced with the approach slab.

51-5.03E Paving Notch ExtensionsThe construction joint between the paving notch extension and the existing abutment must comply withthe specifications for horizontal construction joints in section 51-1.03D(4). Patch spalls in the existingpaving notch when placing the paving notch extension.

The surface temperature must be at least 40 degrees F during concrete placement. Contact surfaces toreceive concrete may be damp but not saturated.

Retempering of concrete is not allowed. Finishing tools cleaned with water must be thoroughly driedbefore working concrete.

The Engineer may require you to use a flow-controlled modified material when placing concrete on slopesover 5 percent.

Except for magnesium phosphate concrete, cure the concrete using the curing compound method.

Allow 12 hours between placing the paving notch extension and placing the approach slab.

51-6 MASS CONCRETE51-6.01 GENERAL51-6.01A SummarySection 51-6 includes specifications for placing mass concrete elements.

51-6.01B DefinitionsReserved

51-6.01C SubmittalsSubmit a thermal control plan with design calculations for each mass concrete element. The thermalcontrol plan and the calculations must be sealed and signed by an engineer who is registered as a civilengineer in the State. Submit 6 copies of the control plan and 2 copies of the design calculations. Includethe following:

1. Mix design2. Duration and method of curing3. Maximum allowable temperature differentials between the hottest point of the concrete and the

exterior concrete faces4. Procedures to control concrete temperature differentials at time of placement5. Methods of controlling temperature differentials6. Temperature differential monitoring and recording system details7. Temperature sensor types and locations8. Measures to ensure compliance with maximum temperature and temperature differential

requirements


REVISION 0


Determine the maximum allowable temperature differential assuming cracking due to heat of hydrationmust not occur.

Submit temperature data daily as an informational submittal.

Submit a daily progress report as an informational submittal. A copy of the daily report must be availableat the job site.

Submit a modified thermal control plan to correct deficiencies for replacement mass concrete. Includesupporting calculations.

51-6.01D Quality Control and Assurance51-6.01D(1) GeneralAn engineer who is registered as a civil engineer in the State must:

1. Inspect and test the temperature monitoring and recording systems before concrete placement2. Be present during mass concrete activities3. Provide daily progress reports

51-6.01D(2) Temperature MonitoringProvide a temperature monitoring and recording system for mass concrete elements. The system mustconsist of temperature sensors connected to a data acquisition system. The system must be capable ofrecording, printing, and downloading temperature data to a computer.

Locate temperature sensors within mass concrete elements such that the maximum temperaturedifference within the element is monitored. At a minimum, monitor temperatures at the following locations:

1. Calculated hottest location2. 2 outer faces3. 2 corners except for CIP piling elements4. Top surfaces

Record temperature readings automatically at least every hour. Install a redundant set of sensors nearthe primary set with recording capability. Make records using the redundant set if the primary set fails.

You may discontinue hourly temperature recording under the following conditions:

1. Maximum internal temperature is falling2. Difference between the interior concrete temperature and the average daily air temperature is less

than the allowable temperature differential for 3 consecutive days3. There are no mass concrete elements to be cast adjacent

Protect the temperature sensor wiring to prevent movement during concrete placement. Keep wire runsas short as possible. Do not let the ends of temperature sensors come into contact with concretesupports, forms, or reinforcement.

Do not damage the monitoring and recording system when placing and consolidating concrete.

Correct equipment failures in temperature control and monitoring and recording systems immediately.

The temperature acceptance criteria for mass concrete elements are as follows:

1. Maximum allowable temperature must not exceed 160 degrees F.2. Maximum temperature differential must not exceed that listed in the thermal control plan.



REVISION 0


51-6.03 CONSTRUCTIONYou may use mechanical cooling systems to control internal concrete temperatures during curing.Mechanical cooling systems must comply with the thermal control plan.

Embed the system within mass concrete elements. Surface connections to cooling pipes must beremovable to 4 inches below the concrete surface.

Design the forms such that cooling or temperature monitoring is not disturbed during form removal.

Secure the cooling pipes to prevent movement during concrete placement. Replace damaged coolingpipes immediately.

Pressure test the cooling system for leaks at 30 psi for 30 minutes before placing concrete. Coolant mustbe circulating when concrete placement starts.

Pressure grout the cooling pipes after cooling is complete. Use a nonshrink grout mix complying withASTM C 1107 and ASTM C 827 for 0.0 percent shrinkage and 0.0 percent minimum and 4.0 percentmaximum expansion. Place the grout under the manufacturer’s instructions.

After the surface connections are removed, the holes must be reamed and filled with mortar.

Remove mass concrete elements that do not comply with the temperature acceptance criteria.

51-6.04 PAYMENTNot Used

52 REINFORCEMENT52-1 GENERAL

52-1.01 GENERAL52-1.01A SummarySection 52-1 includes general specifications for fabricating and placing reinforcement.

52-1.01B Definitionsaffected zone: Portion of the reinforcing bar where any properties of the bar, including the physical,

metallurgical, or material characteristics, have been changed by:

1. Fabrication or installation of a splice. The weld and 1 inch adjacent to the weld is part of the affectedzone.

2. Manufacturing process for headed bar reinforcement.

lot:

1. 150 count, or fraction thereof, of the same type of mechanical splice coupler model for each:1.1. Bar size1.2. Bar deformation pattern1.3. Hoop diameter

2. 150 count, or fraction thereof, of CJP butt-welded splices or resistance-butt-welded splices for each:2.1. Bar size2.2. Hoop diameter

3. 150 count, or fraction thereof, of headed bar reinforcement for each:3.1 Bar size3.2 Head size3.3 Head type3.4 Method of manufacture3.5 Heat number of bar material3.6 Heat number of head material


REVISION 0


A reinforcing bar with a head on each end is counted as 2 headed reinforcing bars for establishingand testing production lots.

52-1.01C Submittals52-1.01C(1) GeneralNot Used

52-1.01C(2) Certificate of ComplianceSubmit a certificate of compliance for each shipment of reinforcement.

If requested, submit the following:

1. Copy of the certified mill test report for each heat and size of reinforcing steel showing physical andchemical analysis

2. 2 copies of a list of all reinforcement before starting reinforcement placement

52-1.01C(3) Shop Drawings52-1.01C(3)(a) GeneralSubmit shop drawings for reinforcing steel. Notify the Engineer of the submittal. Include the submittal

date and contents in the notification.

52-1.01C(3)(b) Temporary Support SystemIf a portion of an assemblage of bar reinforcing steel exceeds 20 feet in height and is not encased inconcrete, submit shop drawings and design calculations for a temporary support system.

The temporary support system must be designed to:

1. Resist all expected loads2. Prevent collapse or overturning of the cage

If form installation or other work requires changes to or the temporary release of any part of the temporarysupport system, the shop drawings must show the support system to be used during these changes orthe temporary release.

The minimum horizontal wind load to be applied to the reinforcing steel assemblage or to a combinedassemblage of reinforcing steel and forms must be the sum of the products of the wind impact area andthe applicable wind pressure value for each height zone.

The wind impact area is the total projected area of the assemblage normal to the direction of the appliedwind. Determine wind pressure values using the following table:

Wind PressureHeight zone, H

(feet aboveground)

Wind pressurevalue(psf)

0 30 2030 < H 50 25

50 < H 100 30H > 100 35

52-1.01D Quality Control and AssuranceNot Used



REVISION 0


52-1.02B Bar ReinforcementReinforcing bars must be deformed bars complying with ASTM A 706/A 706M, except you may usedeformed or plain bars complying with ASTM A 615/A 615M, Grade 40 or 60, as reinforcement in thefollowing:

1. Slope and channel paving2. Minor structures3. Sign and signal foundations4. Roadside rest facilities5. Concrete barrier Type 50 and 60

You may use plain bars complying with ASTM A 706/A 706M for spiral or hoop reinforcement instructures and concrete piles.

You may substitute welded wire reinforcement for reinforcing bars in the following:

1. Slope paving and lined ditches2. Retaining walls3. Concrete barriers4. Sidewalks, curbs, and gutters on structures5. Nonstructural aesthetic additions6. Culvert headwalls, end walls, and wing walls7. Shotcrete8. Deck overlays

Substituted welded wire reinforcement must be on an equivalent area basis and placed as ordered. If thewelded wire reinforcement does not provide the required area of steel, supplement it with reinforcing bars.

52-1.02C Welded Wire ReinforcementWelded wire reinforcement must comply with ASTM A 185/A 185M or ASTM A 497/A 497M.

52-1.02D Reinforcing WireReinforcing wire must comply with ASTM A 82/A 82M.


52-1.03B CleaningBefore concrete is placed, the reinforcement to be embedded must be free of mortar, oil, dirt, excessivemill scale and scabby rust, and other coatings that would destroy or reduce the bond.

52-1.03C BendingDo not bend or straighten bars in a way that damages the material. Do not use bars with kinks orimproper bends.

Hooks and bends must comply with the Building Code Requirements for Structural Concrete published byACI.

52-1.03D PlacingFirmly and securely hold reinforcement in position by:

1. Wiring at intersections and splices.2. Using precast mortar blocks or ferrous metal chairs, spacers, metal hangers, supporting wires, or

other authorized devices strong enough to resist crushing under applied loads. Do not use aluminum,plastic, or wood supports.

Do not place bars on layers of fresh concrete as the work progresses.

BENDING OF 135 DEGREE HOOK GRANTED W/CONDITIONS STATED IN DRFI-10014 (DRFI-10014)


REVISION 0


Metal supports must have a clear cover of at least 1 inch. Do not consider protective coatings on metalsupports when determining clear cover. Where the clear cover to reinforcement shown or orderedexceeds the minimum specified clear cover, increase the clear cover for metal supports accordingly.

The center-to-center spacing of parallel bars must be at least 2.5 times the bar diameter.

The clear distance between bundles of bars and adjacent bundles or single bars must be at least:

1. 1.5 times the maximum size of the coarse aggregate2. 2 times the larger bar diameter for 2-bar bundles3. 2.5 times the larger bar diameter for 3-bar bundles

Tie bundle bars together at not more than 6-foot centers.

Unless otherwise shown, reinforcement must have a 2-inch clear cover measured from the surface of theconcrete to the outside of the reinforcement.

Adjust or relocate reinforcement in post-tensioned concrete during the installation of prestressing ducts ortendons as required to provide described clearances to the prestressing tendons, anchorages, jacks, andequipment. Obtain authorization for any adjustments or relocations.

Unless otherwise shown, anchor each unit of wire spiral reinforcement at both ends by a 135-degreehook with a 6-inch tail hooked around an intersecting longitudinal bar. Discontinuities in spiralreinforcement may be made only where shown or authorized. The spiral on each side of a discontinuity ora lap splice is a separate unit. Where discontinuities in spiral reinforcement are not allowed, splice spiralreinforcement under section 52-6. Lap splices in spiral reinforcement must be lapped at least 80 wirediameters.

Roll welded wire reinforcement flat before placing concrete. Secure welded wire reinforcement in placewith devices that prevent the reinforcement's vertical and transverse movement.

Do not tack weld on reinforcing bars unless shown.

For column and pile bar reinforcing cages measuring 4 feet in diameter and larger:

1. Tie all reinforcement intersections with double wire ties on at least 4 vertical bars of each cageequally spaced around the circumference.

2. Tie at least 25 percent of remaining reinforcement intersections in each cage with single wire ties.Stagger tied intersections from adjacent ties.

3. Provide bracing to avoid collapse of the cage during assembly, transportation, and installation.

52-2 EPOXY-COATED REINFORCEMENT AND EPOXY-COATED PREFABRICATEDREINFORCEMENT

52-2.01 GENERAL52-2.01A General52-2.01A(1) SummarySection 52-2.01 includes general specifications for fabricating and placing epoxy-coated reinforcementand epoxy-coated prefabricated reinforcement.

The substitution of welded wire reinforcement for bar reinforcement specified in 52-1.02B is not allowedfor epoxy-coated bar reinforcement or epoxy-coated prefabricated bar reinforcement.


52-2.01A(3) Submittals52-2.01A(3)(a) GeneralNot Used


REVISION 0


52-2.01A(3)(b) Epoxy Powder Test SamplesNot Used

52-2.01A(3)(c) Patching Material Test SamplesNot Used

52-2.01A(3)(d) Quality Assurance Test SamplesSubmit test samples of epoxy-coated reinforcement and epoxy-coated prefabricated reinforcement.

52-2.01A(4) Quality Control and AssuranceThe following must be on the Authorized Material List:

1. Epoxy powder2. Corrosion protection covering for splices

52-2.01B MaterialsExcept for field welding of butt splices, complete welding of the reinforcement before epoxy coating.

If a part of a bar or wire is described to be epoxy coated, coat the entire bar unless the bar or wire isspliced outside the limits of epoxy coating, in which case epoxy coating is not required on the part of thebar or wire beyond the splice.

Do not store reinforcement within 1,000 feet of ocean or tidal water for more than 2 months.

Patching material and the patching process must be suitable for field application.

52-2.01C ConstructionExcept for lap splices, cover splices of reinforcement with a corrosion protection covering. Install coveringunder the manufacturer’s instructions.

52-2.02 EPOXY-COATED REINFORCEMENT52-2.02A General52-2.02A(1) SummarySection 52-2.02 includes specifications for fabricating and placing epoxy-coated reinforcement.

In a freeze-thaw area, epoxy coat the following:

1. All longitudinal and transverse reinforcement in a bridge deck 12 inches or less in thickness2. Longitudinal and transverse reinforcement within 6 inches of the top surface of a bridge deck greater

than 12 inches in thickness3. Reinforcement that extends to within 6 inches of the top surface of the bridge deck4. Reinforcement within or that extends to within 6 inches of the top surface of abutment backwalls,

when the top surface of the backwall is at deck level5. Reinforcement in concrete barriers6. Reinforcement at locations shown


52-2.02A(3) SubmittalsSubmit a certificate of compliance for each shipment of epoxy-coated reinforcement. Include with thesubmittal:

1. Certification that the coated reinforcement complies with ASTM A 775/A 775M for bar reinforcementor ASTM A 884/A 884M, Class A, Type 1, for wire reinforcement

2. All certifications specified in ASTM A 775/A 775M for bar reinforcement or ASTM A 884/A 884M forwire reinforcement


REVISION 0


Perform qualification testing and certifications required by ASTM A 775/A 775M and ASTM A 884/A 884Mat an authorized laboratory.

Submit a certificate of compliance for the patching material that includes a certification that the patchingmaterial is compatible with the epoxy powder to be used.

Instead of providing a certification for the patching material, you may identify on the container that thepatching material is compatible with the epoxy powder to be used.

52-2.02A(4) Quality Control and AssuranceFurnish two 30-inch test samples of each size from each shipment of epoxy-coated reinforcement to thejob site.

Before transporting test samples:

1. Securely bundle and package the 2 test samples in a way that preserves their condition duringtransportation

2. Identify each test sample by shipment and Contract number using weatherproof markings3. Attach a completed Sample Identification Card to the test samples

The Department tests the test samples.

Test samples must comply with the requirements for coating thickness and coating adhesion specified inASTM A 775/A 775M for bar reinforcement or ASTM A 884/A 884M Class A, Type 1 for wirereinforcement, as follows:

1. If both test samples comply with the requirements, the Department accepts all epoxy-coatedreinforcement represented by the test.

2 If both test samples do not comply with the requirements, the Department performs 1 additional teston the reinforcement of the same size from the same shipment. This additional test consists of testing2 test samples, randomly selected by the Engineer, for coating thickness and adhesion. If both testsamples do not comply with the specified requirements, the Department rejects all epoxy-coatedreinforcement represented by the test.

52-2.02B MaterialsEpoxy-coated reinforcement must comply with:

1. ASTM A 775/A 775M for bar reinforcement2. ASTM A 884/A 884M, Class A, Type 1, for wire reinforcement

Fabrication and job site handling of epoxy-coated bar reinforcement must comply with ASTM D 3963/D3963M.

Coating must be light green.

52-2.02C ConstructionIf damage to the coating occurs during field bending, patch the area immediately.

Job site practices must comply with sections X1.3.1 through X1.3.15 of appendix X1 of ASTM A 884/A884M for wire reinforcement, except replace the term "should" with the term "must."

52-2.03 EPOXY-COATED PREFABRICATED REINFORCEMENT52-2.03A General52-2.03A(1) SummarySection 52-2.03 includes specifications for fabricating and placing epoxy-coated prefabricatedreinforcement.



REVISION 0


52-2.03A(3) SubmittalsSubmit a certificate of compliance for each shipment of epoxy-coated reinforcement. Include with thesubmittal:

1. Certification that the coated reinforcement complies with ASTM A 934/A 934M for bar reinforcementor ASTM A 884/A 884M Class A, Type 2 for wire reinforcement

2. All certifications specified in ASTM A 934/A 934M for bar reinforcement or ASTM A 884/A 884M forwire reinforcement

Perform qualification testing and certification required by ASTM A 934/A 934M and ASTM A 884/A 884Mat an authorized laboratory.

Submit a certificate of compliance for the patching material that includes a certification that the patchingmaterial is compatible with the epoxy powder to be used.

Instead of providing a certification for the patching material, you may identify on the container that thepatching material is compatible with the epoxy powder to be used.

52-2.03A(4) Quality Control and AssuranceFurnish two 30-inch-long test samples of each size from each shipment to the job site of epoxy-coatedprefabricated reinforcement.

Before transporting test samples:

1. Securely bundle and package the 2 test samples in a way that preserves their condition duringtransportation

2. Identify each test sample by shipment and Contract number using weatherproof markings3. Attach a completed Sample Identification Card to the test samples

The Department tests the test samples.

Test samples must comply with the requirements for coating thickness and coating adhesion specified inASTM A 934/A 934M for bar reinforcement or ASTM A 884/A 884M Class A, Type 2 for wirereinforcement, as follows:

1. If both test samples comply with the requirements, the Department accepts all epoxy-coatedreinforcement represented by the test.

2 If both test samples do not comply with the requirements, the Department performs 1 additional teston the reinforcement of the same size from the same shipment. This additional test consists of testing2 test samples, randomly selected by the Engineer, for coating thickness and adhesion. If both testsamples do not comply with the specified requirements, the Department rejects all epoxy-coatedreinforcement represented by the test.

52-2.03B MaterialsEpoxy-coated prefabricated reinforcement must comply with:

1. ASTM A 934/A 934M for bar reinforcement2. ASTM A 884/A 884M, Class A, Type 2, for wire reinforcement

Coating must be purple or gray.

52-2.03C ConstructionDo not bend epoxy-coated prefabricated bar or wire reinforcement after coating application.

Job site practices must comply with sections X2.3.1 through X2.3.15 of appendix X2 of ASTM A 934/A934M for bar reinforcement, except replace the term "should" with the term "must."

52-3 GALVANIZED BAR REINFORCEMENTNot Used


REVISION 0


52-4 STAINLESS STEEL BAR REINFORCEMENTNot Used

52-5 HEADED BAR REINFORCEMENTNot Used

52-6 SPLICING52-6.01 GENERAL52-6.01A SummarySection 52-6 includes specifications for splicing bar reinforcement.

Reinforcing bar splices consist of lap splices, service splices, or ultimate butt splices.


52-6.01C Submittals52-6.01C(1) GeneralSection 52-6.01C applies if service splices or ultimate butt splices are used in the work.

52-6.01C(2) Certificate of ComplianceSubmit a certificate of compliance for each shipment of splice material. Include with the submittal:

1. Type or series identification of the splice material, including tracking information for traceability2. Grade and size number of reinforcement to be spliced3. Statement that the splice material complies with the type of mechanical splice on the Authorized

Material List4. For resistance-butt-welded material:

4.1. Heat number4.2. Lot number4.3. Mill certificates

52-6.01C(3) Welder and Welding Procedures QualificationsSubmit welder and welding procedure qualifications as an informational submittal.

52-6.01C(4) Splice Prequalification ReportFor each splice type to be used in the work, submit a splice prequalification report for service splices andultimate butt splices that includes:

1. Copy of the coupler manufacturer's product literature giving complete data on the splice material andinstallation procedures

2. Names of the operators who will be performing the splicing3. Descriptions of the positions, locations, equipment, and procedures that will be used in the work4 Certified test results from the authorized laboratory for the prequalification splice test samples5. Certifications from the fabricator for operator and procedure prequalification

52-6.01C(5) Weld Flash Removal ProcessSubmit a proposed weld flash removal process. The submittal must show that the process produces asmooth profile that can be successfully epoxy coated under section 52-2.

Removal of the weld flash must produce a smooth profile free of any sharp edges that would preventproper coating of the reinforcement such that:

1. Ultimate tensile strength and elongation properties of the bar are not reduced2. Outside radius of the flash at any point along the circumference of the bar is not:

2.1. Less than the nominal radius of the bar2.2. Greater than 3/16 inch beyond the nominal radius of the bar


REVISION 0


52-6.01C(6) Production Test ReportSubmit a production test report for each lot prepared by the laboratory performing the testing. The reportmust be signed by an engineer who represents the laboratory and is registered as a civil engineer in theState.

Allow 3 business days for the Engineer's review.

Each report must include:

1. Lot number and location2. Bar size3. Splice type4. Mechanical splice length5. Test specimen length6. Physical condition of splice test sample7. Notable defects8. Total measured slip9. Ultimate tensile strength of each splice10. For ultimate butt splices:

10.1. Location of visible necking area10.2. Largest measured strain

You may encase splices in concrete:

1. After submitting the production test report for review2. Before receiving notification from the Engineer that the production test report is authorized3. Before submitting the production test report for review for splices made vertically at the job site in or

above their final positions for bar reinforcement of columns or CIP concrete piles

52-6.01C(7) Quality Assurance Test SamplesSubmit test samples for QA testing to METS.

Include copies of the certificates of compliance with the QA test samples for mechanical splices andresistance-butt-welded splices.

52-6.01C(8) Splice Rejection ReportFor a rejected lot, submit a splice rejection report.

Allow 3 business days for the Engineer's review.

52-6.01C(9) Radiographic Film Developing Process RecordsIf requested, submit records of radiographic film developing processes and any chemical changes to thedeveloping processes.

52-6.01D Quality Control and Assurance52-6.01D(1) GeneralSection 52-6.01D applies if service splices or ultimate butt splices are used in the work.

Assign a splicing QC manager.

If a lot of splices is rejected, do not use the rejected lot or any subsequent lots until:

1. QC manager performs a complete review of your QC process for these splices2. You prepare a splice rejection report describing the cause of the failure for the splices in the rejected

lot and provisions for preventing similar failures in future lots3. Engineer has notified you that the splice rejection report is authorized


REVISION 0


Before testing resistance-butt-welded splice test samples of reinforcement to be epoxy coated, removethe weld flash using the authorized process for flash removal.

The following must be on the Authorized Material List:

1. Mechanical couplers2. Fabricators of resistance-butt-welded splices

You may encase splices in concrete before receiving notification of the QA test results from the Engineer.

If you encase any splices in concrete before receiving notification from the Engineer, you will not berelieved of your responsibility for incorporating material into the work that complies with the Contract.

Section 11-3.02 does not apply to resistance-butt-welded splices.

52-6.01D(2) Operator and Procedure PrequalificationBefore performing any service or ultimate butt splicing, obtain certifications from the fabricator forprequalification of the operators and the procedures to be used in the work.

For each bar size of each splice type to be used, each operator must prepare:

1. 2 prequalification splice test samples2. 2 additional prequalification splice test samples if using splices dependent on bar deformations

Splice test samples must have been prepared and tested no more than 2 years before the submittal ofthe splice prequalification report.

Splice test samples and testing must comply with the production testing requirements specified in section52-6.01D(4) for the type of splice to be used in the work.

52-6.01D(3) Welder and Welding Procedure QualificationsBefore performing any CJP butt welds, qualify welders and welding procedures under AWS D1.4.

Qualify welders and welding procedures on splice test samples of the type to be used in the work.

52-6.01D(4) Production Testing52-6.01D(4)(a) GeneralProduction testing includes total slip testing, service splice testing, and ultimate butt splice testing.

Splice test samples must comply with California Test 670.

For splicing new reinforcement to existing reinforcement, make splice test samples using onlyreinforcement having the deformation pattern of the new reinforcement.

Before transporting splice test samples to an authorized laboratory or to METS:

1. Securely bundle and package the 4 test samples for each test in a way that preserves their conditionduring transportation

2. Identify each splice test sample by location and Contract number using weatherproof markings3. Attach a completed Sample Identification Card to each bundle

Test production splice test samples:

1. At a laboratory on the Authorized Laboratory List2. In the condition received3. Under California Test 670

Before performing service splice or ultimate butt splice testing, perform total slip testing on the servicesplice or ultimate but splice test samples as specified in section 52-6.01D(4)(b).

Do not perform tests on splice test samples from bundles containing fewer than 4 test samples.


REVISION 0


At least 5 business days before performing any testing at the authorized laboratory, notify the Engineerof:

1. Date of the testing2. Location of the authorized laboratory where the tests will be conducted3. Number of lots to be tested

If a production test for a lot is rejected, repair or replace reinforcing bars from which test samples wereremoved before the Engineer selects additional splices from this lot for more testing.

52-6.01D(4)(b) Total Slip TestingExcept for mechanical lap, welded, or hoop splices, test 1 of the 4 splice test samples for total slip.

If the splice test sample exceeds the total slip value specified in section 52-6.02B, test the 3 remainingtest samples for total slip. If any of the 3 remaining test samples exceed the specified total slip value, theDepartment rejects all splices in the lot.

52-6.01D(4)(c) Service Splice TestingA service splice test consists of preparing and testing 4 splice test samples for each lot of completedsplices.

Prepare the test samples using the same splice material, position, operators, location, equipment, andprocedures to be used in the work.

Splice test samples must comply with the requirements specified in 52-6.02C as follows:

1. If only 1 splice test sample complies with the requirements, the Department rejects all splices in thelot.

2. If only 2 splice test samples comply with the requirements, perform 1 additional test on the same lotof splices. This additional test must consist of tensile testing 4 splice test samples, randomly selectedby the Engineer and removed by you from the lot of completed splices. If any of the 4 splice testsamples from this additional test do not attain the specified minimum tensile strength, the Departmentrejects all splices in the lot.

3. If 3 or more splice test samples comply with the requirements, the Department accepts all splices inthe lot.

52-6.01D(4)(d) Ultimate Butt Splice Testing52-6.01D(4)(d)(i) GeneralAn ultimate butt splice test consists of removing and testing 4 splice test samples from each lot ofcompleted splices.

After completing the splices in a lot, including any required epoxy coating, notify the Engineer that thesplices are ready for testing. Except for hoops, the Engineer selects splice test samples at the job site.The Engineer selects splice test samples for hoops at the job site or fabrication plant.

After being notified, the Engineer randomly selects the 4 splice test samples to be removed by you andplaces tamper-proof markings or seals on them.

If the tamper-proof marking or seal is disturbed before testing, the Department rejects the splice testsamples.

At rupture, splice test samples must comply with the requirements specified in section 52-6.02D asfollows:

1. If only 1 splice test sample complies with the requirements, the Department rejects all splices in thelot.

2. If only 2 splice test samples comply with the requirements, perform 1 additional ultimate butt splicetest on the same lot of splices. If any of these 4 splice test samples do not comply with the specifiedrequirements, the Department rejects all splices in the lot.


REVISION 0


3. If 3 or more splice test samples comply with the requirements, the Department accepts all splices inthe lot.

The Department does not require ultimate butt splice testing on repaired splices from a lot unless anadditional ultimate butt splice test is required on the same lot of splices. If this additional test is required,the Engineer may select any repaired splice for the additional test.

If splices are made vertically at the job site in or above their final positions for bar reinforcement ofcolumns or CIP concrete piles, instead of removing the splice test samples from the completed lot, youmay prepare the samples as specified for service splice test samples in section 52-6.01D(4)(c). Test thesplice test samples as specified for ultimate butt splice test samples.

52-6.01D(4)(d)(ii) Radiographic TestingSection 52-6.01D(4)(d)(ii) applies when test samples for CJP butt-welded splices are not removed from alot of completed splices.

Notify the Engineer 48 hours before performing any RT.

Perform RT of CJP butt-welded splices under AWS D1.4:

1. Before tensile testing the splice test samples2. On 25 percent of CJP butt-welded splices from a production lot

The Engineer selects the splices that compose the production lot and the splices within each lot toreceive RT.

If more than 12 percent of the splices radiographically tested in a production lot are defective, perform RTon an additional 25 percent of the splices selected by the Engineer from the same production lot. If morethan 12 percent of the cumulative total of splices tested from the same production lot are defective,perform RT on all remaining splices in the lot.

Repair defects under AWS D1.4.

Radiographic procedures must comply with AWS D1.1 and D1.4.

For field-produced CJP butt welds, do not radiograph more than 1 weld during 1 exposure.

Make radiographs by either X-ray or gamma ray. Each radiograph must have a density of from 2.3 to 3.5in the area of interest. The Department allows a density tolerance of 0.05 for densitometer variations.Gamma rays must be from the iridium 192 isotope and the emitting specimen must not exceed 0.18 inchin the greatest diagonal dimension.

You may add an allowable weld buildup of 0.16 inch to the total material thickness when determining theproper penetrameter selection. The Department does not accept image quality indicator equivalency.

Sufficiently shim penetrameters using a radiographically identical material. Penetrameter image densitiesmust be from 2.0 to 3.6.

Regardless of the reinforcing bar size, radiographic film must be Class 1.

The Department does not allow sight development.

Record the results of radiographic interpretations on a signed certification and keep a copy with the filmpacket.

Technique sheets prepared under ASME Boiler and Pressure Vessel Code, section V, article 2, sectionT-291, must include the developer temperature, developing time, fixing duration, and all rinse times.

52-6.01D(5) Quality Assurance TestingAt the same time you prepare or remove splice test samples for production testing, prepare or remove 4QA splice test samples for:


REVISION 0


1. 1st production test performed2. 1 of every 5 subsequent production tests, or fraction thereof, randomly selected by the Engineer

QA splice test samples must comply with California Test 670.

Secure, identify, and transport QA splice test samples as specified for splice test samples in section 52-6.01D(4).

The Department tests QA service splices and QA ultimate butt splices as specified for production testingin section 52-6.01D(4).

The Department will notify you of the QA test results for each bundle of 4 test samples of splices within 3business days after METS receives the bundle unless more than 1 bundle is received on the same day, inwhich case allow 2 additional business days for each additional bundle received.


52-6.02B Total Slip RequirementsThe total slip must not exceed the values shown in the following table when tested under California Test670:

Total SlipReinforcing bar no. Total slip (inch)

4 0.0205 0.0206 0.0207 0.0288 0.0289 0.02810 0.03611 0.03614 0.04818 0.060

52-6.02C Service Splice RequirementsService splices must develop a minimum tensile strength of 80,000 psi.

52-6.02D Ultimate Butt Splice RequirementsWhen tested under California Test 670, ultimate butt splice test samples must demonstrate necking aseither of the following:

1. For "Necking (Option I)," the test sample must rupture in the reinforcing bar outside of the affectedzone and show visible necking.

2. For "Necking (Option II)," the largest measured strain must be at least:2.1 Six percent for no. 11 and larger bars2.2 Nine percent for no. 10 and smaller bars

52-6.03 CONSTRUCTION52-6.03A GeneralButt-welded or mechanical splices not shown as requiring a service splice or an ultimate butt splice mustcomply with the specifications for service splices.

Do not place splices at a location shown as a no-splice zone.


REVISION 0


Reinforcing bars may be continuous where splices are shown. If splice locations are not shown,determine splice locations using commercial lengths where practicable.

Unless another option is shown, stagger splices in adjacent reinforcing steel. The minimum distancebetween staggered:

1. Lap splices or mechanical lap splices must be the same as the length required for a lap splice in thelargest bar

2. Butt splices must be 2 feet measured between the splice midpoints along a line centered between theaxes of the adjacent bars

For reinforcing bars where splice test samples were removed, replace either of the following:

1. Removed portion of the bar or hoop using mechanical ultimate butt splices2. Bar or hoop in kind

52-6.03B Lap SplicingSplices made by lapping must consist of placing reinforcing bars in contact and wiring them togetherwhile maintaining the alignment of the bars and the minimum clearances.

Do not splice reinforcing bars by lapping where you cannot provide a minimum clear distance of 2 inchesbetween the splice and the nearest adjacent bar.

Do not splice nos. 14 and 18 bars by lapping.

For reinforcing bars complying with ASTM A 615/A 615M, Grade 60, or ASTM A 706/A 706M, the lengthof lap splices must be at least:

1. 45 diameters of the smaller bar spliced for reinforcing bars no. 8 or smaller2. 60 diameters of the smaller bar spliced for reinforcing bars nos. 9, 10, and 11

For reinforcing bars complying with ASTM A 615/A 615M, Grade 40, the length of lap splices must be atleast:

1. 30 diameters of the smaller bar spliced for reinforcing bars no. 8 or smaller2. 45 diameters of the smaller bar spliced for reinforcing bars nos. 9, 10, and 11

For splices in bundled bars, the length of the lap splices must be:

1. Same as the length of a single bar lap splice for bundles of 2 bars2. 1.2 times the length of a single bar lap splice for bundles of 3 bars

Lap welded wire reinforcement such that the overlap between the outermost cross wires is at least thelarger of the following:

1. 6 inches2. Spacing of the cross wires plus 2 inches3. Numerical value of the longitudinal wire size (W-size number) times 4.3 divided by the spacing of the

longitudinal wires in inches

52-6.03C Service Splices and Ultimate Butt Splices52-6.03C(1) GeneralService splices and ultimate butt splices must be one of the following:

1. Mechanical splices2. Resistance-butt-welded splices3. CJP butt-welded splices


REVISION 0


52-6.03C(2) Mechanical SplicesPerform service splicing and ultimate butt splicing of mechanical splices:

1. Under the manufacturer's instructions, unless otherwise specified2. Using the manufacturer's standard equipment, jigs, clamps, and other required accessories

Splice devices must have a clear cover of at least 1-3/4 inches measured from the surface of the concreteto the outside of the splice device. To provide the specified clear cover to reinforcement:

1. Adjust or relocate stirrups, ties, and other reinforcement2. Place additional reinforcement, if needed

52-6.03C(3) Resistance-Butt-Welded SplicesIf resistance-butt-welded bar reinforcement is to be epoxy coated, remove the weld flash using theauthorized process for flash removal.

52-6.03C(4) Complete-Joint-Penetration Butt-Welded SplicesCJP butt-welded splices must comply with AWS D1.4.

Use only the joint details and dimensions shown in Figure 3.2 of AWS D1.4. Do not use split pipebacking.

Make butt welds with multiple weld passes without an appreciable weaving motion using a stringer beadhaving a width at most 2.5 times the diameter of the electrode. Perform slagging between each weldpass. Weld reinforcement must not exceed 0.16 inch in convexity.

Electrodes for welding must have a minimum CVN impact value of 27 J at -4 degrees F.

For welding of bars complying with ASTM A 615/A 615M, Grade 40 or 60, the requirements of Table 5.2of AWS D1.4 are superseded by the following: The minimum preheat and interpass temperatures must be400 degrees F for Grade 40 bars and 600 degrees F for Grade 60 bars. Immediately after completing thewelding, cover at least 6 inches of the bar on each side of the splice with insulated wrapping to control therate of cooling. The insulated wrapping must remain in place until the bar has cooled below 200 degreesF.

If welding different grades of reinforcing bars:

1. Electrode must comply with the specifications for Grade 40 bar2. Preheat must comply with the specifications for Grade 60 bar

If any of the specified preheat, interpass, and post weld cooling temperatures are not met, remove theweld and heat-affected-zone metal and reweld the splice.

Protect welding from air currents, drafts, and precipitation to prevent loss of heat or loss of arc shielding.

Do not direct butt splice reinforcing bars by thermite welding.

52-7 STRAY CURRENT PROTECTION52-7.01 GENERAL52-7.01A SummarySection 52-7 includes specifications for installing stray current protection.

Stray current protection consists of one or a combination of the following:

1. Prestress tendon connections2. Bar reinforcing steel connections3. Copper cable to bar reinforcing steel connections4. Pile and concrete epoxy insulation5. Concrete insulation course


REVISION 0


6. Neoprene sheet insulation7. Joint sealant insulation8. Membrane insulation9. Mortar block insulation10. Epoxy-coated reinforcing steel insulation11. Plastic end cover insulators12. Pipe wrapping tape insulation13. Epoxy for insulation of embedded metal materials14. Concrete steel reinforcing bonding15. Ferrous pipes cathodic protection16. Test stations

The types of stray current protection to be installed are shown.


52-7.01C SubmittalsNot Used


52-7.01D(2) Not Used52-7.01D(3) Bar reinforcing Steel ConnectionThe following will be required for the bar reinforcing steel connection:

1. Non-structural welds used for stray current/gounding should be visually approved.2. Reinforcing steel should be Grade-A709.

Visual inspection of completed welds must show no evidence of cracks, lack of fusion, or undercutting


52-7.02B Prestress Tendon ConnectionFor prestress tendon connections, the no. 6 steel wire must comply with ASTM A 82/A 82M, A 510, or A510M.

52-7.02C Bar Reinforcing Steel ConnectionNot Used

52-7.02D Copper Cable to Bar Reinforcing Steel ConnectionMaterials for exothermic welding the copper cable to bar reinforcing steel connections must comply withthe manufacturer's instructions for the mold size and shape, and the charge size and alloy mixture for thepowder.

The copper cable must comply with Section 16645-DB Stray Current and Corrosion Control Systems.

The tape must be commercially available vinyl electrical tape with a thickness of at least 7 mils.

The test box cover and anchorage devices must comply with section 75-1.03. The gasket must be madeof commercially available neoprene.


REVISION 0


52-7.02E Pile and Concrete Epoxy InsulationFor pile and concrete epoxy insulation, epoxy must be commercial quality, nonconductive, and suitablefor adherence to concrete and steel surfaces.

52-7.02F Concrete Insulation CourseConcrete insulation courses must comply with section 51 and contain at least 590 pounds of cementitiousmaterial per cubic yard of concrete.

52-7.02G Neoprene Sheet InsulationFabricate neoprene sheet insulation from sheet neoprene complying with the specifications for neoprenein section 51-2.04.

The sheet must be at least 1/8 inch thick.

52-7.02H Joint Sealant InsulationThe joint sealant insulation must be a single-component nonsag polyurethane sealant complying withASTM C 920.

The primer and backing rod must comply with the joint sealant manufacturer's instructions.

52-7.02I Membrane InsulationMembrane insulation must comply with the specifications for dampproofing or preformed membranewaterproofing in section 54.

52-7.02J Mortar Block InsulationMortar block insulation must contain at least 760 pounds of cementitious material per cubic yard. Theblocks must be dense, homogeneous, and watertight.

52-7.02K Epoxy-Coated Reinforcing Steel InsulationEpoxy-coated reinforcing steel insulation must comply with section 52-2.

If a coupling nut is used at an attachment between an approach slab and an abutment, the nut must beepoxy coated either before or after fabrication.

52-7.02L Plastic End Cover InsulatorsThe plastic end cover insulators must be of the type commercially available to protect workers fromprotruding reinforcing bars. Bond the covers to the reinforcing bars with commercially available epoxy thatis compatible with the plastic covers.

52-7.02M Pipe Wrapping Tape InsulationFor pipe wrapping tape insulation, the tape must be pressure-sensitive PVC or polyethylene tape with anominal thickness of 20 mils. Use a primer as recommended by the manufacturer of the tape.

52-7.02N Epoxy for Insulation of Embedded Metal MaterialsFor insulation of embedded metal materials, epoxy must be commercial quality, nonconductive, andsuitable for adhering to metal surfaces.

Instead of epoxy coating hanger rods, you may use commercial quality neoprene bushings around thepipe at strap supports.

Instead of epoxy coating metal parts of joint seal assemblies in contact with concrete, you may apply aheavy coat of bituminous paint.



REVISION 0


52-7.03B Prestress Tendon ConnectionDo not perform welding on the prestress anchorage devices. Do not perform arc welding on theprestressing strand.

Connect collector wire to the prestressed strand by gas welding. Do not gas weld until the tendons aregrouted and have cured for at least 24 hours. You may join 2 wire pigtail ends by gas welding at anystage of the work.

Oxyacetylene welding must comply with the best standards of the industry. Use gas welding rodscomplying with Class RG45 (steel rods).

52-7.03C Bar Reinforcing Steel ConnectionWeld bars and splices by the manual shielded metal-arc process before installing any prestressingstrands. Use low-hydrogen electrodes complying with the specifications for E7016 electrodes in AWSA5.1/A5.1M.

52-7.03D Copper Cable to Bar Reinforcing Steel ConnectionFusion weld the copper cable to the bar reinforcing steel by an exothermic type welding process.

Apply commercially available rubber splicing compound to the welded connection.

Apply 2 layers of tape, each half lapped.

52-7.03E Pile and Concrete Epoxy InsulationAbrasive blast clean concrete surfaces on which epoxy insulation is to be applied to the extent that cleanaggregate is exposed.

Apply the epoxy by brush or other means that will completely and uniformly cover the surfaces.

Remove lifting anchors as specified for their removal in a corrosive environment in section 49-2.04B(2).

52-7.03F Concrete Insulation CourseExcavate and backfill for concrete insulation course under section 19-3.

The joint between the concrete insulation course and the footing must comply with the specifications forhorizontal construction joints in section 51-1.03D(4), except abrasive blast cleaning is not required.

52-7.03G Neoprene Sheet InsulationFor neoprene sheet insulation, lap each successive sheet securely to the preceding sheet by at least 6inches.

52-7.03H Joint Sealant InsulationAbrasive blast clean and prime concrete surfaces to receive joint sealant insulation.

52-7.03I Membrane InsulationThe exposed surfaces of membrane insulation must be of uniform height above ground without unsightlybulges, depressions, or other imperfections.

Membrane insulation must comply with the specifications for dampproofing or preformed membranewaterproofing in section 54.

52-7.03J Mortar Block InsulationNot Used

52-7.03K Epoxy-Coated Reinforcing Steel InsulationFor a coupling nut epoxy coated after fabrication, apply the epoxy by brush or other means that willcompletely and uniformly cover the surfaces in contact with concrete.


REVISION 0


52-7.03L Plastic End Cover InsulatorsUse enough epoxy to ensure no voids exist between the plastic end cover insulators and the reinforcingbars.

52-7.03M Pipe Wrapping Tape InsulationFor pipe wrapping tape insulation, apply 1 layer of tape half lapped.

52-7.03N Epoxy for Insulation of Embedded Metal MaterialsFor embedded metals insulated with epoxy:

1. Prepare galvanized surfaces under section 59-3.03.2. Apply the epoxy by brush or other means to completely and uniformly cover the surfaces in contact

with concrete.

53 SHOTCRETENot Used

54 WATERPROOFING54-1 GENERAL

54-1.01 GENERALNot Used

54-2 ASPHALT MEMBRANE WATERPROOFING AND DAMPPROOFINGNot Used

54-3 PREFORMED MEMBRANE WATERPROOFINGNot Used

54-4 WATERPROOFING AND COVER54-4.01 GENERALSection 54-4 includes specifications for applying membrane waterproofing and protective cove to decksurfaces of railroad underpasses.

Furnish and apply the waterproofing and cover under the AREMA Manual for Railway Engineering.


54-4.02B MembraneThe waterproofing membrane must consist of butyl rubber secured with an authorized adhesive.

You may substitute ethylene propylene diene monomer (EPDM) for the butyl rubber if it complies with thespecifications for butyl rubber.

Comply with the AREMA Manual for Railway Engineering, chapter 8, part 29, for:

1. Butyl rubber membrane2. Adhesive3. Splicing cement4. Butyl gum splicing tape5. Antibonding paper6. Fibered aluminum roof coating

The butyl rubber membrane must be at least 0.060 inch thick.


REVISION 0


54-4.02C Protective CoverThe protective cover must comply with the AREMA Manual for Railway Engineering, chapter 8, part 29,and must consist of 2 layers of asphaltic panels applied with adhesive and sealing compound to a totalthickness of at least 3/4 inch.

Sealing compound for joints and edges must be compatible with:

1. Membrane2. Adhesive used to fasten the membrane to the deck3. Splicing cement4. Protective cover panels

The individual panels must be 3/8 inch thick.

The installed panels must be at least 4 by 8 feet except as cut for closures.

Ship and store the panels on smooth, flat surfaces.

If the panels are shipped with an inert material between the sheets to prevent sticking, remove the inertmaterial before installation.

54-4.03 CONSTRUCTION54-4.03A GeneralDo not apply the membrane waterproofing until you are prepared to place the protective cover within ashort enough time such that the membrane is not damaged by workers, equipment, exposure toweathering, or any other cause. Repair or replace damaged membrane.

Sweep or air blow the concrete surfaces to receive the seal to clean them of dirt, dust, gravel, looseconcrete particles, and other extraneous materials, and remove projections or fill depressions that coulddamage the membrane.

The horizontal surfaces of the finished waterproofing must be free from depressions and pockets. Themembrane must be carefully turned into drainage fittings. Take special care to make the waterproofingeffective at the following locations:

1. Along the sides and ends of girders2. At stiffeners, gussets, expansion joints, offsets in ballast retainers, and other discontinuities

For retainer-buffers and headers, use no. 1 structural grade Douglas fir timbers pressure treated underAWPA U1, Use Category UC4B, Commodity Specification A, except do not use chromated copperarsenate. For the anchor bolt assemblies associated with retainer-buffers and headers, use commercial-quality, hot-dip galvanized steel bolts, plates, and sheet metal.

54-4.03B Butyl Membrane WaterproofingThe surface to be waterproofed must be dry at the time of membrane application.

Do not apply the membrane when the atmospheric temperature is below 34 degrees F.

Apply the membrane using the following procedure:

1. Position and draw the membrane sheets tight without stretching.2. Roll 1/2 of the membrane uniformly in a direction away from the starting edge or subsequent splice.3. Apply the adhesive to the exposed deck area with a squeegee at a rate of at least 1 gallon per 100

square feet of deck surface.4. Allow the adhesive to dry to a tack-free condition.5. Unroll and press the membrane firmly and uniformly in place, avoiding trapping of air.6. Repeat the same procedure for the remaining 1/2 of the membrane sheet, avoiding wrinkles and

buckles. Position each succeeding sheet to fit the previously installed sheet and splice the sheets.


REVISION 0


Membrane splices must be tongue-and-groove type as shown in figure 8-29-3, no. 3, of the AREMAManual for Railway Engineering, chapter 8, part 29.

Splice the membrane sheets using the following procedure:

1. Clean all seam, lap, and splice areas with heptane, hexane, toluene, trichloroethylene, or whitegasoline using a clean cloth, mop, or similar synthetic cleaning device.

2. Spread splicing cement continuously on the seam, lap, and splice areas at a uniform rate of at least 1gallon per 75 square feet based on both mating surfaces.

3. After the cement has dried to a tack-free condition, apply butyl gum splicing tape to the cementedarea of the membrane, extending the tape to at least 1/8 inch beyond the edges of the splice and lapareas.

4. Roll or press the tape firmly into place to obtain full contact, avoiding bridging and wrinkles.5. Reinforce corner splices with 2 continuous layers of rubber membrane over 1 layer of butyl tape.

Flash all projections, such as pipes, conduits, and sleeves, passing through the membrane waterproofingwith prefabricated or field-fabricated boots, fitted coverings, or other devices as necessary to providewatertight construction. Use butyl gum tape between layers of rubber membrane.

Patch holes in the membrane sheeting under the manufacturer's instructions with a minimum overlap of 4inches.

Before laying the membrane across a transverse expansion joint in the bridge deck, lay and center on thejoint a 12-inch-wide, galvanized, 22-gage steel sheet covered by an 18-inch-wide strip of antibond paper.

54-4.03C Asphaltic Protective CoverBefore placing the protective cover:

1. Thoroughly clean the surface of the applied membrane of dirt, dust, loose or unsound concrete, andother extraneous material

2. At transverse expansion joints in the bridge deck, lay and center on the joint above the membrane a12-inch-wide, galvanized, 22-gage steel sheet covered by an 18-inch-wide strip of antibond paper

Lay the panels with 2 superimposed layers. Offset the joints in the 2nd layer from the joints in the 1stlayer by approximately 1/2 the width of the panel.

Lay the panels in an adhesive coating using the following procedure:

1. Apply the adhesive with a squeegee at a rate of at least 1 gallon per 100 square feet of deck surface.2. As you lay successive panels, thoroughly coat the edges and ends of adjacent panels already laid

with a sealing compound.3. Lay the panels tightly against those previously laid such that the sealing compound completely fills

the joints and squeezes out at the top.4. After all of the panels have been laid, fill any voids between the panels with sealing compound.

Where an edge or protrusion of asphaltic panels is exposed to prolonged sunlight, coat the area withfibered aluminum roof coating.

55 STEEL STRUCTURES55-1 GENERAL

55-1.01 GENERAL55-1.01A SummarySection 55-1 includes general specifications for furnishing and erecting structural steel or metalwork.

Connection details for highway bridges must comply with AASHTO LRFD Bridge Design Specificationswith California Amendments.


REVISION 0


Design details, fabrication, and workmanship for railway bridges must comply with chapter 15 of theAREMA Manual for Railway Engineering.

55-1.01B Definitionsthread stickout: The threaded end of a bolt projecting past the outer nut face.

unidentified stock material: Material that cannot be identified with certified mill test reports.

55-1.01C Submittals55-1.01C(1) GeneralSubmit a calibration certificate for each bolt tension measuring device and calibrated wrench before use.

Submit details for methods of straightening material to be fabricated.

Submit a welding QC plan with the steel structures shop drawings. List methods and personnel to satisfythe requirements of AWS D1.5.

Submit reports from testing performed on fastener components and assemblies before shipment to thejob site. Test reports must include the rotational capacity lot numbers and the reports listed in the"Certification," "Report," "Number of Tests and Retests," and "Certification and Test Report" sections ofthe referenced ASTM standards. For ASTM A 307 anchor bolts, include chemical composition and carbonequivalence for each heat of steel.

Submit copies of mill orders when orders are placed.

Submit certified mill test reports before fabrication. Include CVN impact test results if impact testing isspecified. Include grain size if fine grain steel is specified.

Submit certificates of compliance for materials used in the work except for unidentified stock material.

55-1.01C(2) Shop DrawingsSubmit shop drawings for steel structures to OSD, Documents Unit. Notify the Engineer of the submittal.Include the submittal date and contents in the notification. Allow 45 days for the Department's review forhighway bridges and 60 days for railway bridges. Submit 6 sets for highway bridges and 10 sets forrailway bridges. Submit 6 to 12 sets, as requested by the Engineer, to OSD, Documents Unit after reviewfor final authorization.

Include the following in the shop drawings:

1. Sequence of shop and field assembly and erection2. Welding sequences and procedures3. Layout drawing of the entire structure with locations of butt welded splices4. Locations of temporary supports5. Vertical alignment of girders at each stage of erection6. Match-marking diagrams7. Details for connections not shown or dimensioned on the plans8. Details of allowed options incorporated in the work9. Direction of rolling of plates where orientation is specified

Submit camber calculations with the shop drawings.

55-1.01C(3) Check TestingSubmit test samples for check testing to METS. Submit test samples for each heat of maximum thicknessof:

1. Tension flanges and webs of fracture critical members2. Tension flanges and webs of curved girders3. Tension hanger plates


REVISION 0


Furnish plates, shapes, or bars containing test samples from the mill with extra length to provide forremoval of check samples at the fabrication site. Samples may be cut from either end.

You may remove test samples at the rolling mill. Remove samples from the mill plate that will be strippedby the fabricator to produce the designated plate. Take samples from any location within the plate. Markdonor plates with the same identifying numbers as the test samples.

Remove material for test samples in the Engineer's presence. Test samples for plates over 24 incheswide must be 14 by 18 inches with the long dimension transverse to the direction of rolling. Test samplesfor other products must be 18 inches long taken in the direction of rolling with a width equal to the productwidth.

Submit test samples before fabricating into components. Mark samples with the direction of rolling, heatnumbers, and plate numbers using paint or indelible marking material. You may steel stamp samples inone corner of the plate instead of marking.

Results of check testing are reported to you no sooner than 20 days after delivery to test laboratory. Formultiple samples submitted on the same day, an additional day is added for every 2 samples submittedand the test report is made for the group of samples.

55-1.01D Quality Control and Assurance55-1.01D(1) GeneralWelder qualification and inspection must comply with AWS D1.5.

The results of the Department's tensile and impact testing of test samples must not vary more than 5percent below the specified minimum or 5 percent above the specified maximum requirements. If initialtest results vary more than 5 percent but less than 10 percent from the specified requirements, a retestmay be performed on another test sample from the same heat and thickness.

Each manual torque wrench must have a dial gage or digital read out. Any electric, pneumatic, orhydraulic calibrated wrench used to tension fasteners must have an adjustable control unit to shut off thewrench at the desired torque.

Bolt tension measuring devices and calibrated wrenches must be calibrated not more than 1 year beforeuse and at least yearly during the project. The calibration must be performed by an authorized laboratoryor authorized repair and calibration center approved by the tool manufacturer. Certification equipment andcalibration standards must be traceable to NIST.

Calibrate bolt tension measuring devices to be accurate to within 1 percent of actual tension. Calibrationmust consist of at least 4 evenly spaced verification readings performed over a range of 20 to 80 percentof full scale.

Calibrate calibrated wrenches to be accurate to within 2 percent of actual torque. Calibration must consistof at least 4 evenly spaced verification readings performed over a range of 20 to 100 percent of full scale.If a torque multiplier is used, calibrate the torque multiplier and calibrated wrench as a unit. Includesockets and extensions of the same length to be used in the work during calibration. Adjust themanufacturer's torque multiplier during calibration so that the product of the torque multiplier and the inputcalibrated wrench reading is within 2 percent of actual torque value. Use this system only as calibrated.

55-1.01D(2) CertificationsNot Used

55-1.01D(3) Source Quality Control55-1.01D(3)(a) GeneralThe Department inspects structural steel at the fabrication site. Notify the Engineer when materials aredelivered to the fabrication site. Allow at least 10 days between giving notice and starting fabrication.


REVISION 0


In addition to NDT requirements in AWS D1.5, ultrasonically test 25 percent of all main member tensiongroove welds in material over 1/2 inch thick. The Engineer determines the location of all NDT testing forwelding.

55-1.01D(3)(b) Rotational Capacity Testing55-1.01D(3)(b)(i) GeneralPerform rotational capacity testing on HS fastener assemblies before shipment to the job site.

Test each combination of bolt production lot, nut lot, and washer lot as an assembly. Assign a rotationalcapacity lot number to each combination of lots tested. Mark each shipping unit of fastener assemblieswith the rotational capacity lot number.

Test 2 fastener assemblies from each lot. Both fastener assemblies tested from a rotational capacity lotmust pass for the lot to be acceptable.

Use 1 hardened washer under the nut for testing.

Test zinc-coated assemblies after lubrication.

You do not need to test cap screws or bolts used for slip base plates.

Test procedures specified are for A 325 bolts.

55-1.01D(3)(b)(ii) Long Bolt TestUse the following equipment for long bolt testing:

1. Calibrated bolt tension measuring device.2. Hand wrench or suitable tool for turning bolt.3. Calibrated dial or digital torque wrench with socket.4. Spacer washers or bushings. Spacer washers or bushings must have the same inside diameter and

an equal or larger outside diameter as the appropriate hardened washers complying with ASTM F436.

5. Steel beam or member to which the tension measuring device will be attached. The member must beaccessible from the ground.

Use the following procedure:

1. Measure and record the bolt length from the bolt washer face to the end of the shank.2. Install the nut on the bolt such that the first 3 to 5 full threads closest to the bolt head are between the

nut face and bolt head.3. Measure and record the length of bolt thread protruding beyond the outer nut face. If the nut cannot

be fully threaded onto the bolt, test the assembly under section 55-1.01D(3)(b)(iii).4. Insert the bolt into the tension measuring device. Install the hardened washer and any required

spacers under the nut to produce the thread length recorded in step 3 above.5. Tighten the nut using a hand wrench to the minimum snug tension shown in the following table:


REVISION 0


Table 1 A325 Snug-Tight Tension ValuesBolt diameter

(inches)Minimum snug tensiona

(kips)1/2 15/8 23/4 37/8 41 5

1-1/8 61-1/4 71-3/8 91-1/2 10

aThe tension may exceed the table 1 value by atmost 2 kips.

6. Match-mark the assembly as follows:6.1. Place a mark on 1 corner of the nut.6.2. Place a heavy reference line on the face plate of the tension measuring device that aligns with

the mark on the nut.6.3. Place a line that aligns with the mark on the nut across the flat end of the bolt shank or on the

exposed portions of the threads of tension control bolts.6.4. Place a mark on the outside of the turning socket. The mark must be aligned with the mark on

the nut corner and be visible when the nut is being turned.6.5. Make an additional mark on the face plate at the required rotation shown in the following table

clockwise from the heavy reference line:

Table 2 Required Nut Rotation for Rotational Capacity Tests a,b

Bolt lengthc Required rotation (turn)4 bolt diameters or less 2/3

More than 4 and at most 8 bolt diameters 1More than 8 and at most 12 bolt

diametersd1-1/3

aNut rotation is relative to bolt, regardless of the element being turned.For bolts installed by 1/2 turn or less, the tolerance is ±30 degrees; forbolts installed by 2/3 turn or more, the tolerance is ±45 degrees.bApplicable only to connections in which all material within the grip ofthe bolt is steel.cAs measured in step 1 above.dIf the bolt length exceeds 12 diameters, the required rotation must bedetermined by actual tests in a suitable tension device simulating siteconditions.

7. Turn the nut to attain the minimum tension for the applicable bolt diameter shown the following table:


REVISION 0


Table 3 A325 Minimum Tension ValuesBolt diameter (inches) Minimum tension (kips)

1/2 125/8 193/4 287/8 391 51

1-1/8 561-1/4 711-3/8 851-1/2 103

8. After attaining the tension shown in table 3, record in ft-lb the moving torque required to turn the nutand the corresponding bolt tension. Measure torque with the nut in motion. Use this correspondingbolt tension to determine T using the following formula:

T = b x d/48

whereb = corresponding bolt tension in poundsd = bolt diameter in inches

9. Turn the nut until the rotation shown in table 2 is attained. Measure the rotation from the heavyreference line on the face plate. Record the bolt tension.

10. Remove the nut and examine the threads on the nut and bolt.

Acceptance criteria is as follows:

1. Moving torque recorded in step 8 must be less than or equal to the calculated value T.2. Bolt tension recorded in step 9 must be at least the turn test tension value shown in table 4.3. Nut is removed from the bolt with no signs of thread stripping or galling on the bolt or nut.4. Bolt must not shear or fail during the test.5. Assembly must not seize before the final rotation in step 8 is attained.

Table 4 A325 Turn Test Tension ValuesBolt diameter (inches) Turn test tension (kips)

1/2 145/8 223/4 327/8 451 59

1-1/8 641-1/4 821-3/8 981-1/2 118

55-1.01D(3)(b)(iii) Short Bolt TestUse the following equipment for short bolt testing:

1. Calibrated dial or digital torque wrench with socket.2. Hand wrench.3. Spacer washers or bushings. Spacer washers or bushings must have the same inside diameter and

an equal or larger outside diameter as the appropriate hardened washers complying with ASTM F436.


REVISION 0


4. Steel plate or girder. This member must have a thickness that provides the required number ofthreads within the bolt grip as specified in procedure step 2 of section 55-1.01D(3)(b)(ii).

Use the following procedure:

1. Measure and record the bolt length from the bolt washer face to the end of the shank.2. Install the nut on the bolt. The first 3 to 5 full threads must be located between the nut washer face

and the bolt washer face. Measure and record the length of bolt thread protruding beyond the outernut face.

3. Install the bolt into the hole in the plate or girder. The hole must be 1/16 inch larger than the nominalbolt diameter. Install the hardened washer and any required spacers to produce the thread lengthrecorded in step 2.

4. Tighten the nut snug tight using a hand wrench. Do not exceed 20 percent of the maximum allowabletorque value shown in the following table.

Table 5 A325 Maximum Allowable TorqueBolt diameter (inches) Torque (ft-lb)

1/2 1455/8 2853/4 5007/8 8201 1220

1-1/8 15001-1/4 21301-3/8 28001-1/2 3700

5. Match-mark the assembly as follows:5.1. Place a mark on 1 corner of the nut.5.2. Place a heavy reference line on the steel plate or girder that aligns with the mark on the nut.5.3. Place a line that aligns with the mark on the nut across the flat end of the bolt shank or on the

exposed portions of the threads of tension control bolts.5.4. Place a mark on the outside of the turning socket that aligns with the mark on the nut. This

mark must be visible when the nut is being turned.5.5. Make 2 additional small marks on the steel plate or girder, one at 1/3 of a turn and one at 2/3 of

a turn clockwise from the heavy reference line on the steel plate or girder.

6. Tighten the nut to the rotation value shown in table 6. Measure the rotation from the heavy referenceline on the steel girder or plate. Do not allow the bolt head to turn during tightening.

Table 6 Nut Rotation Requiredfor Turn-of-Nut Installation a,b

Bolt lengthc Required rotation (turn)4 bolt diameters or less 1/3

aNut rotation is relative to bolt regardless of theelement being turned. For bolts installed by 1/2 turn orless the tolerance is ±30 degrees.bApplicable only to connections in which all materialwithin the grip of the bolt is steel.cMeasured in step 1.

7. Record in ft-lb the moving torque required to turn the nut when the rotation value shown in table 6 isattained.

8. Tighten the nut further to the rotation value shown in table 7. Measure the rotation from the heavyreference line on the steel girder or plate. The line on the end of the bolt shank or on the exposedthreads of tension control bolts must remain in alignment with the start line.


REVISION 0


Table 7 Required Nut Rotationfor Rotational Capacity Test

Bolt lengtha Required rotation (turn)4 bolt diameters or less 2/3

aMeasured in step 1.

9. Remove the nut and examine the threads on the nut and bolt.

Acceptance criteria is as follows:

1. Moving torque recorded from step 7 must be less than or equal to the maximum allowable torqueshown in table 5.

2. Nut is removed from the bolt with no signs of thread stripping or galling on the bolt or nut after therotation in step 8 has been attained.

3. Bolt must not shear or fail during the test.4. Assembly must not seize before the final rotation in step 8 is attained.

55-1.01D(4) Field Quality Control55-1.01D(4)(a) GeneralPerform job site HS fastener testing in the Engineer's presence.

The Engineer rejects uninstalled fasteners in the same rotational capacity lot as fasteners that fail a jobsite installation tension test or rotational capacity test.

Perform additional rotational capacity tests, installation tension tests, and tests to determine newinspection torques on rotational capacity lots if any of the following occur:

1. Any fastener is not used within 3 months after arrival on the job site2. Fasteners are improperly handled, stored, or subjected to inclement weather before final tightening3. Changes are noted in original surface condition of threads, washers, or nut lubricant4. Required inspections are not performed within 48 hours after all fasteners in a joint have been

tensioned

55-1.01D(4)(b) Rotational Capacity TestingPerform rotational capacity testing on each rotational capacity lot under section 55-1.01D(3)(b) beforeinstallation.

55-1.01D(4)(c) Installation Tension TestingPerform installation tension testing on each rotational capacity lot before installation.

Test 3 representative HS fastener assemblies under section 8 of Specification for Structural Joints UsingASTM A 325 or A 490 Bolts of the RCSC. For short bolts, test 3 representative HS fastener assembliesunder "Pre-Installation Verification Procedures" of Structural Bolting Handbook of the Steel StructuresTechnology Center.

If using direct tension indicators, perform installation verification tests under appendix X1 of ASTM F 959except that bolts must be initially tensioned to a value 5 percent greater than the minimum required bolttension.

55-1.01D(4)(d) Verification Tension TestingVerify minimum fastener tension in HS bolted connections no later than 48 hours after all fasteners in aconnection have been tensioned.

The Engineer selects fasteners to be tested. Perform testing such that the Engineer can read the torquewrench or access direct tension indicator gaps during testing.


REVISION 0


Check 10 percent of each type of fastener assembly in each HS bolted connection for minimum tensionunder section 10 of Specification for Structural Joints Using ASTM A 325 or A 490 Bolts of the RCSC.Check at least 2 assemblies per connection. For short bolts determine the arbitration torque using steps 1through 7 of 'Arbitration of Disputes, Torque Method-Short Bolts' in Structural Bolting Handbook of theSteel Structures Technology Center.

Determine and use a separate inspecting torque for each different rotational capacity lot of fasteners.

55-1.02 MATERIALS55-1.02A General55-1.02A(1) GeneralMaterials must comply with the requirements shown in the following tables:

Structural SteelMaterial Specification

Carbon steel ASTM A 709/A 709M, Grade 36 orASTM A36/A36M a

HS low alloy columbiumvanadium steel

ASTM A 709/A 709M, Grade 50 orASTM A 572/A 572M, Grade 50 a

HS low alloy structural steel ASTM A 709/A 709M, Grade 50W, Grade HPS50W, or ASTM A 588/A 588M a

HS low alloy structural steelplate

ASTM A 709/A 709M, Grade HPS 70W

High-yield strength quenchedand tempered alloy steelplate suitable for welding

ASTM A 709/A 709M, Grade 100 and Grade100W or ASTM A 514/A 514M a

aGrades you may substitute for the equivalent ASTM A 709 steel subject to themodifications and additions specified and to the requirements of ASTM A 709.

FastenersMaterial Specification

Steel fastener componentsfor general applications:

Bolts and studs ASTM A 307Anchor bolts ASTM F 1554 or ASTM A 307, Grade CHS bolts and studs ASTM A 449, Type 1HS threaded rods ASTM A 449, Type 1HS nonheaded anchorbolts

ASTM F 1554, Grade 105, Class 2A

Nuts ASTM A 563, including appendix X1a

Washers ASTM F 844Components of HS steelfastener assemblies for usein structural steel joints:

Bolts ASTM A 325, Type 1Tension control bolts ASTM F 1852, Type 1Nuts ASTM A 563, including appendix X1a

Hardened washers ASTM F 436, Type 1, Circular, includingS1 supplementary requirements

Direct tension indicators ASTM F 959, Type 325, zinc-coatedaZinc-coated nuts tightened beyond snug or wrench tight must be furnished witha dry lubricant complying with supplementary requirement S2 in ASTM A 563.


REVISION 0


Other MaterialsMaterial Specification

Carbon steel for forgings,pins, and rollers

ASTM A 668/A 668M, Class D

Alloy steel for forgings ASTM A 668/A 668M, Class GPin nuts ASTM A 36/A 36MCarbon-steel castings ASTM A 27/A 27M, Grade 65-35, Class 1Malleable iron castings ASTM A 47/A 47M, Grade 32510 (Grade 22010)Gray iron castings ASTM A 48, Class 30BCarbon steel structural tubing ASTM A 500, Grade B or ASTM A 501Steel pipea ASTM A 53, Type E or S, Grade B;

ASTM A 106, Grade B; or ASTM A 139, Grade BStud connectors AWS D1.5

aHydrostatic testing will not apply.

55-1.02A(2) Charpy V-notch RequirementsStructural steel plate used for the following components must comply with longitudinal CVN impact valuesshown in the following table:

1. Tension members, tension flanges, eyebars, and hanger plates2. Splice plates of tension members, tension flanges, and eyebars

Material complying withASTM A 709/A 709M

CVN impact value(ft-lb at temperature)

Grade 36 15 at 40 ºFGrade 50a (Thickness up to 2 inches) 15 at 40 ºFGrade 50Wa (Thickness up to 2 inches) 15 at 40 ºFGrade 50a

(Thickness over 2 inches up to 4 inches )20 at 40 ºF

Grade 50Wa (Thickness over 2 inches up to 4inches)

20 at 40 ºF

Grade HPS 50Wa (Thickness up to 4 inches) 20 at 10 ºFGrade HPS 70W (Thickness up to 4 inches) 25 at -10 ºFGrade 100 (Thickness of 2-1/2 inches or less) 25 at 0 ºFGrade 100W (Thickness over 2-1/2 inches up to4 inches)

35 at 0 ºF

aIf the material yield point is more than 65,000 psi, reduce the temperaturefor the CVN impact value 15 degrees F for each increment of 10,000 psiabove 65,000 psi.

Determine CVN values under ASTM E 23. Sampling procedures must comply with ASTM A 673. Use theFrequency H (Heat) testing for steels complying with ASTM A 709/A 709M, Grades 36, 50, 50W, andHPS 50W. Use the Frequency P (Piece) testing for steels complying with ASTM A 709/A 709M, GradesHPS 70W, 100, and 100W.

For fracture critical members, minimum CVN impact values are specified in these specifications.

55-1.02A(3) Structural SteelUnless otherwise described, structural steel plates, shapes, and bars must comply with ASTM A 709/A709M, Grade 50. You may increase girder flange plate thickness and length if the change does notdecrease any portion of the plates in detailed thickness. For continuous girders, increases in the length ofgirder flange plates that change locations of butt welds between different thicknesses of flange platesmust be authorized before fabrication.


REVISION 0


Stud type shear connectors longer than 8 inches may consist of multiple shorter studs connected withcomplete joint penetration welds.

All structural steel that is precut before arrival at the fabrication site must be cut so that the primarydirection of rolling is parallel to the direction of the main tensile or compressive stress in the member.

Do not use coiled steel plate for the following items:

1. Flanges or eyebars2. Hanger plates3. Splice plates for flanges or eyebars

For members shown, you may substitute rolled shapes for welded sections and welded sections for rolledshapes if the substituted members comply with the following:

1. Depth, width, and average thicknesses are at least equal to the replaced shape or section2. For welded sections, the flanges are welded to the web with continuous fillet welds on each side of

the web3. Strength classification of the material is not reduced

55-1.02A(4) Bearing PadsElastomeric bearing pads must comply with section 51-3.02.

55-1.02A(5) CastingsSteel, gray iron, and malleable iron castings must have adequate continuous fillets cast in place inreentrant angles. The radius of curvature of the exposed surface of a fillet will define the fillet size. Thesize of fillets must be at least 1/2 the thickness of the thinnest adjoined member but not less than 1/2inch.

Finished casting dimensions must be at least equal to the dimensions shown. Castings must be not morethan 7.5 percent overweight. Large castings must be suspended and hammered over their entire area.Cracks, flaws, or other defects must not be present after hammering.

55-1.02A(6) Unidentified Stock MaterialYou may use unidentified stock material on non–fracture critical members if:

1. No more than 30,000 pounds is used.2. Unidentified stock material is segregated from all other materials used in the work.3. Material is authorized before fabrication.

The Engineer may select samples for testing from each piece of unidentified stock material proposed foruse. Testing of samples must be performed by an authorized laboratory under the applicable ASTM.

55-1.02A(7) Miscellaneous MaterialsCaulking must be polysulfide or polyurethane caulking complying with ASTM C 920, Type S, Grade NS.

55-1.02B Fabrication55-1.02B(1) GeneralRolled material must be straight before being laid out or worked. Subassemblies and completed membersmust be straight before being incorporated into the work. The Department rejects straightened materialshowing evidence of damage.

Cut and fabricate steel plates for flanges, eyebars, hanger plates, and splice plates for flanges andeyebars such that the primary direction of rolling is parallel to the direction of the main tensile orcompressive stress in the member.

Mechanically cut edges must be clean cut without torn or ragged edges.


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Weld girder stiffeners shown as bearing stiffeners. Ends of stiffeners shown as tight-fit must bear on thegirder flange with at least point bearing. Local clearances between the end of the stiffener and the girderflange must be at most 1/16 inch. Except where stiffeners are cut back, caulk gaps between stiffenerends and the girder flange before painting.

Build floor beams, stringers, and girders having end connection angles to exact length back to back ofconnection angles. If end connections are faced, the finished angle thickness must be at least that shownon the shop drawings.

Finished members must be true to line and free from twists, bends, and open joints.

Match-mark connecting parts that are preassembled for setting up for welding or for drilling or reamingholes for field connections.

Where galvanizing is described, galvanize structural steel under section 75-1.05.

Neatly finish exposed parts of the work. Slightly round edges, sharp corners, and edges marred, cut, orroughened during handling or erection.

Clean and paint iron and steel surfaces under section 59.

55-1.02B(2) Flatness of Faying and Bearing SurfacesSurfaces of bearing and base plates and other metal surfaces that contact each other or ground concretesurfaces must be flat to within 1/32 inch in 12 inches and 1/16 inch overall.

Surfaces of bearing and base plates and other metal bearing surfaces that contact mortar, preformedfabric pads, or elastomeric bearing pads must be flat to within 1/8 inch in 12 inches and 3/16 inch overall.

You may heat straighten steel slabs not in contact with other metal bearing surfaces if the abovetolerances are met.

55-1.02B(3) Bent PlatesCold-bent load-carrying rolled steel plates must comply with the following:

1. Direction of bending must be at right angles to the direction of rolling2. Radius of bend measured to the concave face must comply with ASTM A6/A6M3. Before bending, the corners of the plate must be rounded to a 1/16-inch radius throughout that

portion of the plate where bending is to occur

Plates to be bent to a shorter radius than specified in ASTM A6/A6M must be bent hot. Hot bent platesmust have the direction of bending at right angles to the direction of rolling.

55-1.02B(4) Fastener ThreadsFastener threads for general applications must comply with the following:

1. External threads must comply with the Unified Coarse Thread Series requirements in ANSI B1.1 withClass 2A tolerances before coating with zinc

2. Internal threads must comply with ASTM A 563

Threads for pin ends and nuts 1-1/2 inches or more in diameter must comply with the following:

1. External threads must be Unified Inch Screw Threads, UN Series with 6 threads per inch, complyingwith ANSI B1.1 with Class 2A tolerances

2. Internal threads must be Unified Inch Screw Threads, UN Series with 6 threads per inch, complyingwith ANSI B1.1 with Class 2B tolerances

55-1.02B(5) Pin ConnectionsPins must be:

1. Turned to the dimensions shown


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2. Straight, smooth, and free from flaws3. Have the final surface produced by a finishing cut

In pins more than 9 inches in diameter, bore a full length hole at least 1-7/8 inches in diameter along thepin axis after cooling and before annealing.

Bore holes for pins:

1. True to the diameter specified2. At right angles to the member axis3. Except for pins where non-parallel holes are required, holes must be parallel with each other4. Smooth and straight with the final surface produced by a finishing cut

Coat machined surfaces of pins and holes with an easily removed rust inhibitor.

The distance between holes for pins must not vary by more than 1/32 inch from that shown whenmeasured outside-to-outside for tension members and inside-to-inside for compression members.

The diameter of holes for pins must not exceed the pin diameter by more than 1/50 inch for pins 5 inchesor less in diameter or 1/32 inch for larger pins.

Bore holes for pins in built-up members after assembly. If authorized, you may bore holes beforeassembly if the same degree of accuracy is achieved as boring after assembly.

Bore pin-connected hanger plates in pairs or in stacks bolted or clamped together such that each pair ofhanger plates is matched.

Use pilot and driving nuts for driving pins. Drive pins such that the members will bear fully on them. Forfield assembly use a positive locking device to tighten and secure pin nuts.

55-1.02B(6) Bolted Connections55-1.02B(6)(a) GeneralBolted connections in structural steel joints must be made with HS steel fastener assemblies consisting ofone of the following:

1. HS steel bolt, nut, and hardened washer. You may use a direct tension indicator with the bolt, nut,and hardened washer.

2. Tension control bolt, nut, and hardened washer

If the bolt head is the turned element during installation, perform installation tension testing andverification tension testing, including determining inspection torque, by turning the bolt head.

Each length and diameter of fastener assembly used in any single joint of a HS bolted connection mustbe from the same rotational capacity lot. Keep a record of which lots are used in each joint.

55-1.02B(6)(b) Bolt Holes55-1.02B(6)(b)(i) GeneralBolt holes must be one of the following:

1. Punched full size2. Drilled full size3. Subpunched and reamed4. Subdrilled and reamed

Finished holes for bolts must be:

1. Cylindrical and perpendicular to the plane of the connection2. At most 1/16 inch larger than the nominal bolt diameter3. Clean cut without torn or ragged edges


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4. Without irregularities that prevent solid seating

Holes punched full size, subpunched, or subdrilled must pass a pin 1/8 inch smaller than the nominal holesize without drifting in at least 75 percent of the holes for each connection after assembling and beforeany reaming.

All holes must pass a pin 3/16 inch smaller in diameter than the nominal hole size.

Do not correct mispunched or misdrilled holes by welding unless authorized.

55-1.02B(6)(b)(ii) PunchingDo not punch or subpunch ASTM A 36/A 36M structural steel thicker than 7/8 inch. Do not punch orsubpunch HS structural steel thicker than 3/4 inch.

The diameter of the punching die must not exceed the punch diameter by more than 3/32 inch.

Subpunch holes to be reamed to a diameter 1/4 inch smaller than the finished hole.

55-1.02B(6)(b)(iii) DrillingDrill full-sized holes with the parts assembled or to a steel template with hardened bushings. If authorized,you may drill full-sized holes with gang drill equipment.

The Engineer may request a proof assembly to check the fit of major field connections.

Subdrill holes to be reamed to a diameter 1/4 inch smaller than the finished hole.

Drill through templates after the templates have been firmly clamped or bolted.

If members are drilled while assembled, hold parts together securely during drilling.

You may stack drill plates using gang drills if:

1. Parts are firmly clamped during drilling2. Drill bits remain perpendicular to the work during drilling

55-1.02B(6)(b)(iv) ReamingPerform reaming after built-up members are assembled and firmly bolted together or after templates aresecurely located over the member. Remove shavings after reaming. Mark pieces reamed together so thatthey may be reassembled in the same position. Do not interchange reamed parts.

Reaming templates must:

1. Have hardened steel bushings2. Have accurately dimensioned holes3. Have reference lines for locating templates on members4. Be firmly clamped or bolted in position

Templates used for reaming of matching members or the opposite faces of one member must be exactduplicates.

For reaming holes in assembled material, do not mix full-sized holes with subpunched or subdrilled holes.

55-1.02B(6)(c) InstallationBolted connections using HS fastener assemblies must comply with Specification for Structural JointsUsing ASTM A 325 or A 490 Bolts of the RCSC.

Tension HS bolted connections as slip critical.

Use the same bolt head orientation within a single HS bolted connection.


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Install the hardened washer under the element turned in tightening. Locate nuts on the side of themember not visible from the traveled way. Locate nuts for bolts partially embedded in concrete on theside of the member to be encased in concrete.

If surface moisture is present at a HS bolted connection:

1. Do not install HS fastener assemblies having components furnished with water soluble lubricants.2. The Engineer may require you to perform additional fastener testing if fastener assemblies are

furnished with lubricants not soluble in water.

Seal the sheared ends of tension control bolts with caulking. Caulking must be gray and at least 50 milsthick. Apply caulk to a clean surface the same day the splined end is sheared off.

For all bolts, thread stickout after tensioning must be at least flush with the outer nut face and at most 1/4inch. At least 3 full threads must be located within the grip of the connection. For tension control bolts,measure thread stickout from the outer nut face to the first full thread near the sheared end of the bolt

You may use 1 additional hardened washer under the non-turning element to correct excessive threadstickout.

Thread stickout of studs, rods, and anchor bolts must be at least flush with the outer nut face and at most1 inch.

You may use bolts with diameters up to 1/4 inch larger than the specified bolt diameter if:

1. Authorized2. You comply with the spacing and edge distance requirements for the larger bolt3. Net section is adequate

If using direct tension indicators:

1. Install 1 indicator under each bolt head. The protrusions must contact the bolt head.2. Hold the bolt head stationary and turn the nut.3. Follow the manufacturer's installation procedures.4. Tension bolts in not less than 2 stages until at least 50 percent of the gaps on each indicator are

between 0.000 and 0.005 inch. Indicators with all protrusions completely crushed are rejected.

Do not torque the splined end of tension control bolts before final tensioning.

55-1.02B(7) Welding55-1.02B(7)(a) GeneralWelding must comply with AWS D1.5.

Replace Table 2.2 of AWS D1.5 with the following table:

Base metal thickness of thethicker part joined, inches

Minimum effective partial jointpenetration groove weld sizea, inches

Over 1/4 to 1/2 inclusive 3/16Over 1/2 to 3/4 inclusive 1/4

Over 3/4 to 1-1/2 inclusive 5/16Over 1-1/2 to 2-1/4 inclusive 3/8

Over 2-1/4 to 6 inclusive 1/2Over 6 5/8

aWeld size need not exceed the thickness of the thinner part joined.

Except for welds to reinforce groove welds, minimum fillet weld size must comply with the sizes shown inthe following table:


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Base metal thickness of the thickerpart joined, inches

Minimum fillet weld sizea,inches

To 3/4 inclusive 1/4Over 3/4 5/16

aWeld size need not exceed the thickness of the thinner part joined.

Dimensional details and workmanship for welded joints in tubular and pipe connections must comply withpart A, "Common Requirements for Design of Welded Connections" and part D, "Specific Requirementsfor Design of Tubular Connections," in section 2 of AWS D1.1.

The flat side of butt-welded joints must not deviate from flatness by more than 0.20 inch in a 2-foot lengthcentered over the weld.

Do not weld or tack brackets, clips, shipping devices, or other material not described to any part of thegirders unless shown on the shop drawings.

Grind weld surfaces smooth and flush when NDT is required.

Work complying with sections 56-3 of the Standard Specifications does not need to comply with AWSD1.5.

55-1.02B(7)(b) Backing for WeldsNot Used

55-1.02B(8) Curved GirdersNot Used

55-1.02B(9) Shop AssemblyPrepare and paint contact surfaces of HS bolted connections before assembly. Clean all other metalcontact surfaces thoroughly before assembly.

Preassemble completed subassemblies for structures or units of structures before erection to verifygeometry and to verify or prepare field connections.

Bolted trusses, skew portals, skew connections, rigid frames, bents, and towers must be completelypreassembled, adjusted to line and camber, and prepared for welding or checked for bolt fit beforeerection.

Preassemble long span truss work in lengths of at least 3 abutting panels and adjust members for lineand camber. Prepare joints for welding or drill or ream holes for field connections during preassembly. Forholes previously drilled full size, check holes for bolt fit.

Preassemble bolted splice joints for plate girders and adjust abutting sections for line and camber. Drill orream holes for field connections during preassembly.

Splice joints for welded girders must be preassembled with abutting members, adjusted for line andcamber, and prepared for welding.

Preassembly methods must be compatible with the erection methods used.

Preassemble all machinery completely. Fit bearings to the clearances and alignments specified. Gearreductions and line gears must have gear center distances set and the gears match-marked.

Assemble parts into final positions without damage. Follow all matchmarks. Do not damage or distortmembers when hammering.

Drifting done during assembly must not enlarge bolt holes or distort the metal.

55-1.02C Delivery, Storage, and HandlingMark the weight of any member weighing over 6,000 lb on the member.


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Do not bend, scrape, or overstress members during handling and shipping. The Engineer rejects bent ordamaged members.

Keep structural material clean during loading, transporting, and unloading.

Store structural material above ground on supports. Keep material clean, drained, and protected fromcorrosion. Store girders upright and shored. Support long members on skids placed to prevent deflection.


55-1.03B FalseworkFalsework must comply with section 48-2 except that dead loads consist of the weight of the structuralsteel and portions of the structure supported by the falsework.

Construct falsework and concrete forms on steel structures such that loads applied to girder webs are (1)applied within 6 inches of a flange or stiffener and (2) do not produce local distortion of the web. Providetemporary struts and ties to (1) resist lateral loads applied to girder flanges and (2) prevent appreciablevertical movement between the edge of deck form and the adjacent steel girder.

55-1.03C Erection55-1.03C(1) GeneralYou may erect structural steel girders to provide girder dead load continuity as assumed in design. Iferection procedures provide dead load girder continuity, preassemble members with field joints in a no-load condition in a horizontal or an upright position.

You may erect structural steel girders such that dead load girder continuity is not provided. If erectionprocedures do not provide dead load girder continuity:

1. Submit proposed steel erection procedures with calculations that show girder capacity and geometrywill be correct

2. You may increase cross-sectional areas or change grades of steel to provide the specified capacity ifauthorized

3. After erection, the erected structure must have a load carrying capacity at least equal to the structureshown

55-1.03C(2) Bearings and AnchoragesSet bearing assemblies level. The Engineer provides adjustments to horizontal positions of bearingassemblies due to temperature. Obtain full bearing on the concrete under bearing assemblies.

Immediately before setting bearing assemblies or masonry plates on ground concrete surfaces,thoroughly clean and apply caulking to all contact surfaces.

During welding, protect nonmetallic bearing pads using authorized methods.

The embedded end of each anchor bolt must terminate with a head or a nut and washer. Anchor boltsmust permit true positioning of bearing assemblies.

Mortar placed (1) under masonry plates or bearing assemblies or (2) in anchor bolt sleeves or canistersmust comply with section 51-1.02F except the cement to sand ratio must be 1 to 3. Mortaring andconstructing mortar pads under masonry plates must be done after girder erection and before placingdeck concrete.

If anchor bolts are installed in pipe sleeves or metal canisters, fill the pipes or canisters completely withmortar.

56 SIGNSNot Used


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57 WOOD AND PLASTIC LUMBER STRUCTURESNot Used

58 SOUND WALLSNot Used

59 PAINTING59-1 GENERAL

59-1.01 GENERAL59-1.01A SummarySection 59-1 includes general specifications for painting new installations and repainting existinginstallations.


59-1.01C SubmittalsSubmit a certificate of compliance and MSDS for each shipment of blast cleaning material.

59-1.01D Quality Control and AssuranceMeasure coating dry film thickness with a calibrated Type 2 magnetic film thickness gage under SSPC-PA2 except there is no limit to the number or location of spot measurements that may be requested by theEngineer to verify coating thickness.

Measure coating adhesion strength with a self-aligning adhesion tester under ASTM D 4541.

Measure levels of soluble salts on surfaces using a retrieval method specified in SSPC-Guide 15.

59-1.02 MATERIALS59-1.02A GeneralWater for rinsing and pressure washing must be fresh potable water with a chloride content of not morethan 75 ppm and a sulfate content of not more than 200 ppm. Continuous recycling of rinse water is notallowed. You may collect rinse water in a tank for reuse if test samples meet specified requirements andno water is added to the tank after sampling.

Sealing compound must be a polysulfide or polyurethane type complying with ASTM C 920, Type S,Grade NS, Class 25, Use M.

59-1.02B AbrasivesAbrasives for blast cleaning must be of a grading suitable to produce satisfactory results. Use only thefollowing abrasives unless authorized:

1. Clean dry sand. Do not use unwashed beach sand containing salt or excessive silt.2. Mineral grit.3. Steel shot.4. Steel grit.

Mineral and slag abrasives must comply with the requirements for Class A, Grade 2 to 3 abrasives inSSPC-AB 1 and must not contain hazardous material.

Steel abrasive must comply with SSPC-AB 3. Recycled steel abrasive must comply with SSPC-AB 2.

59-1.02C CoatingsCoatings must comply with section 91.

Coatings selected for use must comply with the volatile organic compound limits specified for the airquality district where the project is located.


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59-1.03 CONSTRUCTION59-1.03A GeneralNotify the Engineer 5 business days before starting work.

Provide protective devices to prevent damage to the work, property, or persons.

59-1.03B Weather ConditionsApply paint only to thoroughly dry surfaces during periods of favorable weather.

Do not perform blast cleaning or apply solvent-borne paint when the atmospheric or surface temperatureis below 36 degrees F or above 100 degrees F or when the relative humidity is more than 85 percent.

Do not apply water-borne paint when the atmospheric or surface temperature is below 51 degrees F orabove 100 degrees F or when the relative humidity exceeds 75 percent.

Except for work within enclosures, do not apply paint if:

1. Freshly painted surfaces may become damaged by rain, fog, or condensation2. Atmospheric temperature or relative humidity will not remain within the specified application

conditions during the drying period3. Steel surface temperature is less than 5 degrees F above the dew point

Repair or replace uncured paint damaged by weather.

If authorized, you may use enclosures to allow painting during inclement weather. Enclosures mustprovide atmospheric conditions within specified limits.

59-1.03C Cleaning59-1.03C(1) GeneralPrepare and clean surfaces before painting.

59-1.03C(2) Pressure RinsingPressure rinsing includes cleaning surfaces using a pressure wash system with a minimum nozzlepressure of 1,160 psi. Keep the nozzle tip from 12 to 18 inches from the surface. The nozzle must have amaximum fan tip angle of 45 degrees.

59-1.03C(3) Pressure WashingPressure washing includes cleaning surfaces using a pressure wash system with a nozzle pressure from2,500 to 5,000 psi and a maximum fan tip angle of 45 degrees.

59-1.03C(4) Steam CleaningSteam cleaning includes cleaning dirt, grease, loose chalky paint, and other foreign material fromsurfaces using steam. Steam temperature at the nozzle must be from 265 to 375 degrees F.

Use a biodegradable detergent during steam cleaning. After steam cleaning, rinse cleaned surfaces withfresh water.

Do not perform steam cleaning more than 2 weeks before painting or other phases of cleaning.

Do not paint steam-cleaned surfaces until they are thoroughly dry and 24 hours have elapsed.

59-1.03C(5) Blast CleaningBlast cleaning includes abrasive blasting surfaces to be painted.

Surfaces to be blast cleaned must be dry.

Prime or treat blast-cleaned surfaces the same day blast cleaning is performed unless otherwiseauthorized.


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59-1.03D PaintingEach spray pot must have an authorized water trap installed.

Thinning of paint is not allowed unless authorized.

Before applying, mix paint using mechanical mixers to thoroughly blend pigment and vehicle together.

Apply paint to clean dry surfaces in a neat and workmanlike manner. Apply by brush, spray, or roller inany combination. Gun extensions are not allowed. Aerosol cans are not allowed.

Brushes must have sufficient bristle body and length to spread paint in a uniform film. Paint must beevenly spread and thoroughly brushed out.

Rollers must not leave a stippled texture in the paint film.

Apply paint to areas not accessible to regular means using daubers, bottle brushes, or other authorizedmethods.

Thoroughly cure each application of paint and correct skips, holidays, thin areas, or other deficienciesbefore the next application. Painted surfaces being covered must be free from moisture and deleteriousmaterial that would prevent bonding of succeeding coats. In spot painting, remove old paint that lifts afterthe first paint application by scraping and repaint the area before the next application.

Pressure rinse painted surfaces before applying additional paint if 7 days or more elapse between paintapplications.

The Engineer may require you to blast clean and reapply paint to areas with runs, sags, thin andexcessively thick areas in the paint film, skips, holidays, or areas of nonuniform appearance.

Repair painted surfaces damaged during work activities with materials and to a condition equal to that ofthe specified coating.

Remove paint or paint stains on surfaces not designated to be painted.

Thoroughly clean painted surfaces after completing painting activities and other work that would depositforeign material on the painted surfaces.

Stencil the month and year of painting on structures at 2 locations selected by the Engineer. Use blockletters 2-1/2 inches high. The paint used must contrast with the background.

59-2 PAINTING STRUCTURAL STEEL59-2.01 GENERAL59-2.01A SummarySection 59-2 includes specifications for preparing and painting structural steel and other metal, exceptgalvanized or thermal spray coated surfaces.


59-2.01C Submittals59-2.01C(1) GeneralSubmit certification showing the maximum allowable dry film thickness for inorganic zinc-rich coatings tobe used on faying surfaces of HS bolted connections as determined under appendix A of Specification forStructural Joints Using ASTM A325 or A490 Bolts of the RCSC.

59-2.01C(2) Mandatory SSPC-QP CertificationsNot Used


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59-2.01C(3) Painting Quality Work PlanSubmit 3 copies of a painting quality work plan for each work item requiring structural steel painting orpaint removal. Allow 20 days for the Department's review. Submit the work plan after attending theprepainting meeting. Include the following:

1. Names of the painting contractor and any subcontractors to be used.2. 1 copy of each applicable ASTM and SSPC specification and qualification procedure.3. Coating manufacturer's guidelines and instructions for surface preparation, painting, drying, curing,

handling, shipping, and storage of painted structural steel. Include testing methods and maximumallowable levels for soluble salts.

4. Materials, methods, and equipment to be used.5. Proof of required SSPC-QP certifications or qualification statements showing compliance with SSPC-

QP certification.6. Methods to control environmental conditions.7. Methods to protect the coating during curing, shipping, handling, and storage.8. Rinse water collection plan.9. Detailed paint repair plan for damaged areas.10. Procedures for containing blast media and water.11. Examples of proposed daily reports for testing to be performed, including type of testing, location, lot

size, time, weather conditions, test personnel, and results.

59-2.01D Quality Control and Assurance59-2.01D(1) GeneralYou must hold following the SSPC certifications in good standing throughout the Contract to perform thefollowing painting activities:

1. For cleaning and painting structural steel in the field, SSPC-QP 12. For removing hazardous coatings from structural steel, SSPC-QP 23. For cleaning and painting structural steel in a permanent painting facility, SSPC-QP 3 or AISC SPE,

Certification P-1 Enclosed

59-2.01D(2) MeetingsBefore starting painting activities, conduct a meeting to discuss painting quality work plan requirements.Meeting attendees must include the Engineer and all painting subcontractors.

59-2.01D(3) Field Quality ControlYou must determine the sequence of testing. The Engineer selects test locations.

If repairs are required, retest rejected areas after completing repairs.

Test blast-cleaned steel for soluble salts using a Class A or B retrieval method before applying theundercoat. Levels of soluble salts must not exceed the lesser of the coating manufacturer'srecommendations or 10 g/sq cm. Perform 3 tests for the first 1,000 sq ft prepared per shift and 1 test foreach additional 1,000 sq ft or portion thereof. Perform at least 2 tests when less than 1,000 sq ft isprepared in a shift. Clean and retest areas represented by soluble salt tests exceeding specified limits.

Test the inorganic zinc undercoat before applying final or finish coats. Perform adhesion and hardnesstesting no sooner than 72 hours after application.

Test the inorganic zinc undercoat as follows:

1. Perform 3 adhesion tests per girder or 1,000 sq ft of painted surface, whichever is less. If less than1,000 sq ft is painted in a work shift, perform 3 tests. The coating must have an adhesion to steel of atleast 600 psi. If 2 or more locations fail adhesion requirements, the area represented by the tests isrejected. If 1 of the locations fails adhesion requirements, test 3 additional locations. If any of theadditional locations fail, the area represented by the tests is rejected. Repair rejected areas by blastcleaning and repainting. Repair test locations meeting adhesion requirements by applying organiczinc-rich primer to the specified dry film thickness.


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2. Test surfaces where finish coats are to be applied for soluble salts. Soluble salt levels must notexceed the lesser of the coating manufacturer's recommendations or 10 g/sq cm. Perform 3 tests forthe first 1,000 sq ft prepared per day and 1 test for each additional 1,000 sq ft or portion thereof.Perform at least 2 tests when less than 1,000 sq ft is prepared in a shift. Clean and retest areasrepresented by soluble salt tests exceeding specified limits.

3. The inorganic zinc coating must exhibit a solid, hard, and polished metal surface when firmly scrapedwith the knurled edge of a quarter before final or finish coats are applied. Repair areas that arepowdery, soft, or do not exhibit a polished metal surface, as determined by the Engineer, by blastcleaning and repainting.

Perform the following additional testing for AASHTO M 300 Type II inorganic zinc primers:

1. Determine the dry-to-solvent insolubility under ASTM D 4752 except use water as the solvent. Theresistance rating must be at least 4. The test rate is 1 test per 500 sq ft or portion thereof. Repairinorganic zinc coating represented by tested areas that fail to meet solvent insolubility requirementsby blast cleaning and repainting.

2. Before applying finish coats, test the surface pH. Wet the surface with deionized water for 15 to 30minutes. Apply pH paper with measuring increments of 0.5 pH units. Take at least 2 pH readings forevery 500 sq ft or portion thereof. If less than 500 sq ft is coated in a single shift, take at least 2 pHreadings. Do not apply finish coats until the surface pH is 7 or less.

Perform the following additional testing for AASHTO M 300 Type I inorganic zinc primers:

1. Determine the dry-to-solvent insolubility under ASTM D 4752. The resistance rating must be at least4. The test rate is 1 test per 500 sq ft or portion thereof. Repair inorganic zinc coating represented bytested areas that fail to meet solvent insolubility requirements by blast cleaning and repainting.

2. Determine surface hardness under ASTM D 3363. Hardness must be 2H or harder. The test rate is 1test per 500 sq ft or portion thereof. Repair inorganic zinc coating represented by tests that fail tomeet surface hardness requirements by blast cleaning and repainting.

59-2.02 MATERIALSInorganic zinc-rich primer used on faying surfaces must comply with the slip coefficient specifications forClass B coatings on blast-cleaned steel in appendix A of Specification for Structural Joints Using A325 orA490 Bolts of the RCSC.

59-2.03 CONSTRUCTION59-2.03A GeneralClean and paint all exposed structural steel and other metal surfaces.

You must provide enclosures for cleaning and painting structural steel. Cleaning and painting of newstructural steel must be performed in a Category I Enclosure as defined in SSPC-QP 3. Maintainatmospheric conditions inside enclosures within specified limits.

Except for blast cleaning within closed buildings, perform blast cleaning and painting during daylighthours.

Coatings for new structural steel must comply with the requirements shown in the following table:


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Table 1 Coatings for New Structural SteelDescription Coating Dry film thickness, mils

All surfaces:Undercoat Inorganic zinc primer,

AASHTO M 300 Type I or II4–8

Finish coata Exterior grade latex,2 coats

2 minimum each coat,4–8 total

Total thickness, all coats 8–14aIf no finish coats are described, a final coat of inorganic zinc primer is required

Coatings for existing structural steel must comply with the requirements shown in the following table:

Table 2 Coatings for Existing Structural SteelDescription Coating Dry film thickness, mils

Connections to newstructural steel:a

Undercoat Inorganic zinc primer,AASHTO M 300 Type I or II

4–8

Finish coatb Exterior grade latex,2 coats

2 minimum each coat,4–8 total

Total thickness, all coats 8–14Other surfaces cleaned tobare metal:

1st undercoat2nd undercoat

State Specification PWB 145State Specification PWB 146

2–32–3

1st finish coat2nd finish coat


1.5–31.5–3

Total thickness, all coats 7–12Existing painted surfacesto be topcoated:

Undercoat State Specification PWB 146 2–31st finish coat2nd finish coat


1.5–31.5–3

Total thickness, new coats 5–9aIncludes the following locations:

1. New and existing contact surfaces2. Existing member surfaces under HS bolt heads, nuts, or washers3. Bare surfaces of existing steel after trimming, cutting, drilling, or reaming4. Areas within a 4-inch radius from the point of application of heat for welding orflame cutting

bIf no finish coats are described, a final coat of inorganic zinc primer is required

59-2.03B Surface Preparation59-2.03B(1) GeneralCorners must be chamfered and without sharp edges.

Condition thermal-cut edges before blast cleaning by shallow grinding or other authorized method toremove the thin, hardened layer resulting from resolidification during cooling.

Remove visually evident base metal surface irregularities and defects under ASTM A 6 or AASHTO M160 before blast cleaning.

After removing material defects exposed by blast cleaning, restore the blast profile by blast cleaning orusing mechanical tools under SSPC-SP 11.


REVISION 0


59-2.03B(2) Cleaning59-2.03B(2)(a) GeneralClean previously painted surfaces by pressure washing or steam cleaning before performing othercleaning or painting activities. Remove gloss from existing paint without removing sound paint. Lightlyroughen remaining areas of gloss using 100-to 200-grit sandpaper. Remove paint that becomes loose,curled, lifted, or that loses its bond after cleaning to sound paint or metal.

After pressure washing or steam cleaning, spot blast clean painted surfaces having rust or foreignmaterial remaining that would hinder bonding of new paint as determined by the Engineer. Spot blastclean surfaces under SSPC-SP 6. For small areas, the Engineer may allow cleaning under SSPC-SP 11.

Remove dirt, loose rust, mill scale, or paint not firmly bonded to surfaces under SSPC-SP 2. Featheredges of remaining paint. Do not use pneumatic chipping hammers unless authorized.

59-2.03B(2)(b) Blast CleaningBlast clean steel surfaces to be coated with inorganic zinc under SSPC-SP 10. After blast cleaning,surfaces must have a dense, uniform, angular anchor pattern of from 1.5 to 3.5 mils when measuredunder ASTM D 4417.

Where shown, spot blast clean existing painted steel surfaces under SSPC-SP 6. After blast cleaning,surfaces must have a dense, uniform, angular anchor pattern of at least 1.5 mils when measured underASTM D 4417.

Seal journals, bearings, motors, and moving parts before blast cleaning near machinery.

Reblast cleaned surfaces that rust or become contaminated before paint is applied.

Do not expose blast-cleaned steel to relative humidity exceeding 85 percent before painting.

59-2.03C Painting59-2.03C(1) GeneralPaintnew structural steel as follows:

1. Apply the total thickness of undercoats before erection. Apply finish coats and final coats aftererection. If a concrete deck is placed on steel members, apply finish and final coats after deckplacement.

2. After erection and deck placement, clean and spot paint areas of damaged or deteriorated coatingand exposed unpainted surfaces with undercoats to the specified thickness before applyingsubsequent coatings.

3. Clean and paint surfaces exposed to the atmosphere and inaccessible for painting after erection withthe full number of coats before erection.

Paint existing structural steel as follows:

1. Precede each undercoat by a stripe coat of undercoat paint on all edges, corners, seams, crevices,interior angles, junctions of joining members, weld lines, and similar surface irregularities. The stripecoat must completely hide the surface being covered and be followed as soon as practical by theundercoat.

2. Apply finish coats after the total dry film thickness of undercoat has been applied.

Caulk contact surfaces of stiffeners, railings, built up members, or open seam more than 6 mils wide withsealing compound or other authorized material. Apply sealing compound no sooner than 72 hours afterthe last application of undercoat unless authorized. Cure the sealing compound as recommended by themanufacturer before performing subsequent painting activities. If no finish coats are applied, the sealingcompound color must be gray.

Limit the thickness of each paint application to allow uniform drying throughout the paint film.


REVISION 0


For existing structural steel, apply all undercoats and the 1st finish coat within 30 days of initial cleaningactivities.

Paint ungalvanized anchor bolt assemblies with 2 applications of organic zinc-rich primer beforeinstallation. You do not need to paint other metal surfaces to be embedded in concrete.

Prepare and paint (1) the bottom surfaces of masonry plates and (2) structural steel surfaces contactingelastomeric bearing pads or preformed fabric pads with the full number of applications before erection.

Except for (1) abutting chord and column splices and (2) column and truss shoe bases, coat machine-finished surfaces with an easily removed rust inhibitor. Paint machine-finished surfaces of iron and steelcastings with 1 coat of shop paint.

Where bridge deck drains are located over steel girders, paint the top and edges of top flanges beneathdrains and for 2 inches on each side of drains before installing the drains.

Paint surfaces of machinery exposed to air with 2 coats of organic zinc-rich primer before installation.Paint exposed surfaces after installation with 2 finish coats of commercial quality gray gloss enamel.

59-2.03C(2) Zinc Coatings59-2.03C(2)(a) GeneralStrain zinc coatings after mixing through a 30-to 60-mesh screen immediately before or when pouring intothe spray pot.

Use an agitating spray pot. The agitator or stirring rod must reach to within 2 inches of the bottom of thespray pot and be moving at all times during painting. The agitator must keep the coating well mixed.

Apply zinc coatings by spray. On areas inaccessible to spray application, you may make limitedapplications when authorized by brush, dauber, or roller.

Zinc coatings must be free from dust, dirt, salt, and other deleterious deposits and thoroughly curedbefore applying subsequent coats.

59-2.03C(2)(b) Inorganic Zinc Undercoat59-2.03C(2)(b)(i) GeneralUse inorganic zinc primer within 12 hours of initial mixing of components.

Apply the undercoat in 2 or more applications within 8 hours of starting blast cleaning.

Blast clean and repaint areas where mudcracking of the undercoat occurs.

Protect surfaces coated with Type II inorganic zinc from conditions that may cause the coating film todissolve. Blast clean and repaint areas of dissolved coating.

Remove dry spray by screening or other methods that minimize surface polishing before applyingadditional coats or final acceptance. Dry film thickness after dry spray removal must comply with thespecified thickness.

For damaged areas of the undercoat, the following apply:

1. If the Engineer determines the damaged area is more than 2 percent of the total undercoated surface,blast clean and repaint damaged areas with inorganic zinc.

2. If the Engineer determines the damaged area is 2 percent or less of the total undercoated surface,you may wire brush the damaged surfaces to remove loose or cracked coating and apply 2 coats oforganic zinc-rich primer.

At faying surfaces, the total undercoat dry film thickness must be from 1 mil to the maximum allowable forClass B coatings as determined by certified testing under appendix A of Specification for Structural JointsUsing A325 or A490 Bolts of the RCSC.

Complete field testing of the undercoat and correct deficiencies before applying subsequent coats.


REVISION 0


59-2.03C(2)(b)(ii) Final CoatApply a final coat of inorganic zinc primer to undercoated surfaces that do not receive finish coats. Usethe same coating as used for the undercoat.

Lightly roughen areas to receive a final coat by abrasive blasting. Use an abrasive no larger than 30mesh. Protect undersurfaces of girder flanges from abrasive blasting.

Apply the final coat in 1 application within 24 hours of roughening. The final coat dry film thickness mustbe from 1 to 3 mils. The total thickness of undercoat and final coat must be from 5 to 9 mils.

59-2.03C(2)(b)(iii) Finish CoatsPressure rinse undercoated surfaces to receive finish coats. Perform pressure rinsing no sooner than 72hours after the final application of undercoat.

The 1st finish coat must be applied within 48 hours of pressure rinsing.

Apply the 1st finish coat in 2 applications. The 1st application consists of a spray-applied mist application.Apply the 2nd application after the mist application has dried to a set-to-touch condition as determinedusing the procedure in section 7 of ASTM D 1640.

Apply the 2nd finish coat after the 1st finish coat has dried 12 hours unless authorized. You may apply the2nd finish coat in a single application.

The 1st finish coat color must match color no. 34272 of FED-STD-595. The 2nd finish coat color mustmatch color no.14090 of FED-STD-595.

60 NOT USED

DIVISION VII DRAINAGE61 CULVERT AND DRAINAGE PIPE JOINTS

Not Used

62 ALTERNATIVE CULVERTSNot Used

63 NOT USED

64 PLASTIC PIPENot Used

65 CONCRETE PIPENot Used

66 CORRUGATED METAL PIPE66-1 GENERAL

66-1.01 GENERAL66-1.01A SummarySection 66-1 includes general specifications for fabricating and constructing corrugated metal pipe andpipe arches for culverts, siphons, drains, slotted pipe, and conduits.

Corrugated metal pipe and pipe arches include all necessary bends, wyes, tees, other branches, concretecollars or tees, and reinforcement.

Corrugated metal pipe arches must comply with section 66-1.02E.


REVISION 0


Excavation, backfill, and shaped bedding must comply with section 19-3.

66-1.01B SubmittalsSubmit a certificate of compliance for:

1. Corrugated steel materials2. Corrugated aluminum materials

66-1.01C Quality Control and Assurance66-1.01C(1) GeneralNot Used

66-1.01C(2) Field Testing of Corrugated Steel Pipe SiphonsPerform field leakage tests on corrugated steel pipe siphons.

Fill the pipe with water to a hydrostatic head of 10 feet above the highest point in the line after the pipehas been laid and backfill has been placed and compacted to a minimum of 2 feet above the pipe.

Conduct a hydrostatic test for a period of not less than 24 hours. Make accurate measurements of thewater required to maintain the test pressure during the test period. Any leakage developed by the testmust not exceed the allowable leakage as computed by the following formula:

E = 0.00002H1/2LDwhere:E = allowable leakage in gpmH = difference in elevation in feet between the water surface at 10 feet above the highest point in

the line and the invert elevation of the pipe at its lowest pointL = length of the culvert or drainage pipe in feetD = internal diameter of the pipe in inches

Furnish all water, materials, and labor for the hydrostatic test. Conduct all hydrostatic tests in thepresence of the Engineer.

Stop any leakage in excess of the allowable leakage as authorized. Repeat the hydrostatic test until thetotal leakage does not exceed the allowable leakage. Stop all obvious leaks whether or not the leakagefrom the line exceeds the allowable leakage.

66-1.02 MATERIALS66-1.02A GeneralCorrugated metal pipe must be corrugated aluminum pipe or corrugated steel pipe as described. Do notmix aluminum and steel materials in any installation, except coupling band fastening hardware.

Ship, handle, and lay corrugated metal materials in a way that prevents bruising, scaling, or breaking ofthe galvanized surface, aluminized surface, or protective coating.

66-1.02B Dimensions and ThicknessDimensions and thicknesses shown are nominal and must comply with AASHTO M 36 for corrugatedsteel pipe and AASHTO M 196 for corrugated aluminum pipe.

The nominal sheet thickness for corrugated metal pipe must be equal to or greater than the nominalthickness described.

Lapped longitudinal seams of riveted pipe arches must be placed in the top arch and must be staggeredso as to alternate on each side of the center of the top arch at least 3 inches.

66-1.02C Protective Coatings, Linings, and PavingsWhere coating, lining, or paving is shown, pipes must be protected with bituminous coating or bituminouslining, or have the invert paved with one or more of the following materials:


REVISION 0


1. Bituminous coating2. Polymerized asphalt invert coating3. Polymeric sheet coating4. Bituminous lining5. Bituminous invert paving

Remove moisture, dirt, oil, unbonded or incompatible paint, grease, alkalies, or other foreign matter fromthe surface to be protected before application of the coating. lining, or paving material.

The bituminous coating for bituminous coated pipes must be applied to the inside and outside of pipes toa minimum thickness of 0.05 inch under AASHTO M 190, Type A.

Coupling bands and connecting hardware for coated pipes must have a protective coating. Couplingbands to be protected by coatings under AASHTO M 190 may be single-dipped with the coating thicknessrequirement waived.

A bituminous lining must be applied to the inside of the pipe over the bituminous coating whereverbituminous lining is shown.

Bituminous paving must be applied to the inside bottom portion of the pipe over the bituminous coatingunder AASHTO M 190, Type C, where bituminous paving is shown.

An asphalt mastic coating may be used instead of the bituminous coating on corrugated steel pipe iflinings and pavings are not required. The asphalt mastic must be placed on the outside surface of thepipe. The inside of the pipe does not need to be coated.

Asphalt mastic coatings must comply with AASHTO M 243, except the asbestos fibers are not required.The asphalt mastic material must be applied uniformly to the surface with a thickness of at least 0.05 inchat any point. The asphalt mastic coating must be applied at the fabrication plant. Pinholes, blisters,cracks, or lack of bond are cause for rejection.

Polymeric sheet coatings must comply with AASHTO M 246. The polymeric sheet coating must beapplied to both sides of the galvanized sheet before corrugating. The thickness of the coating must be atleast 0.010 inch. Pinholes, blisters, cracks, or lack of bond are cause for rejection.

Polymerized asphalt invert coatings must be applied under ASTM A849 for "Invert Paved Type WithPolymer Material (Class P)," except apply the polymerized asphalt coatings by immersion to a thicknessof at least 0.050 inch above the crests and troughs of the corrugations of the interior and exterior invertsincluding the pipe ends. The polymerized asphalt material must comply with ASTM A742/A742M"Requirements for Polymer Coating" and the following:

1. Polymerized asphalt must be hot-applied thermoplastic material containing a minimum of 7.0 percentstyrene-butadiene-styrene block copolymer.

2. Undercutting or delamination from the scribe must not be more than 1/4 inch when a minimum 12-by-12-inch coupon cut from the coated pipe is exposed for 1,000 hours under ASTM B117. The cutedges must be sealed by dipping in a sample of the polymerized asphalt coating heated to themanufacturer's recommended application temperature. The sealed edges must not exhibit corrosionor delamination from the sealed edges following exposure as specified.

For bituminous lined corrugated metal pipe, the rivet heads inside the pipe must be located in the valleyof the corrugation. Provisions must be made at the ends of the pipes to retain bituminous material duringthe fabrication process. Both the inside and outside surfaces must be bituminous coated under AASHTOM 190, Type A. In addition to this coating, the valleys on the inside periphery must be filled by thecentrifugal process with the same type of bituminous material to the extent that the thickness on thecrests of corrugations is at least 1/8 inch. The lining must be smooth and uniform, and its surface must beparallel to a line projected along the crests of the corrugations.

If protective coatings are applied to pipes, clearly identify the thickness of the metal on each section ofpipe and fittings on the inner surface with paint or by other authorized means.


REVISION 0


Repair damaged protective coatings, linings, and invert paving. Use bituminous material under AASHTOM 190 or other authorized materials to repair damaged bituminous coatings. Use asphalt mastic materialunder AASHTO M 243 to repair damaged asphalt mastic coatings. Use tar base material under AASHTOM 243 to repair damaged polymeric sheet coatings. Repair damaged polymerized asphalt coatings underASTM A762/A762M, section 11, "Repair of Damaged Coatings."

66-1.02D Coupling BandsCoupling bands for corrugated metal pipe must comply with either section 66-1.02D or section 61-1.01D(1)(b) of the Standard Specifications.

Choose one of the types of corrugated metal pipe coupling bands shown. The metal bands must becorrugated, dimpled, or otherwise formed in a way that will effectively engage the corrugations of the pipeends.

Coupling bands for corrugated steel pipe must comply with AASHTO M 36. Coupling bands forcorrugated aluminum pipe must comply with AASHTO M 196.

If channel or wing channel coupling bands are used, the interior bend radii of the pipe flange and thechannel must be at least the thickness of the metal of which they are formed.

Joints for siphons must consist of connections made with coupling bands shown for positive joints. Do notuse universal coupling bands.

Joints for siphons and joints for pipes shown as watertight must be watertight under pressure and allconditions of expansion, contraction, and settlement, and must comply with section 61-1.01D(1)(b) of theStandard Specifications for watertightness.

66-1.02E Corrugated Steel Pipe66-1.02E(1) GeneralCorrugated steel materials must comply with AASHTO M 36 and be fabricated from either zinc-coatedsteel sheet or aluminum-coated steel sheet as shown.

Zinc-coated steel sheet must comply with AASHTO M 218, except the coating weight is determined underASTM A123/A123M and A153/A153M.

Aluminum-coated steel sheet must comply with AASHTO M 274.

66-1.02E(2) Fabrication66-1.02E(2)(a) GeneralCorrugated steel pipe must be fabricated by one of the following methods:

1. Riveting2. Helically corrugated steel pipe with a continuous helical lock seam3. Continuous helical welded seam paralleling the corrugation

Pipes fabricated from 0.050-inch thick sheets must be helically corrugated steel pipe with a continuoushelical lock seam or a continuous helical welded seam.

Annular corrugated steel pipe must be fabricated from sheets having either 2-2/3-by-1/2-inch or 3-by-1-inch corrugations.

66-1.02E(2)(b) Fabrication by RivetingPipes fabricated by riveting must comply with AASHTO M 36.

66-1.02E(2)(c) Fabrication by Continuous Helical Seam66-1.02E(2)(c)(i) GeneralHelically corrugated steel pipe must comply with AASHTO M 36.


REVISION 0


Helically corrugated pipe must be fabricated using corrugation profiles and continuous helical seampitches as shown in the following table:

Corrugation ProfileDiameter(Inches)

Nominal pitcha

(inches)Max. pitcha

(inches)Nominal depth

(inches)Seam pitcha

(inches)6 through 18 1-1/2 1-7/8 1/4 1212 through 84 2-2/3 2-3/4 1/2 2448 through 120 3 3-1/4 1 2148 through 120 5 5-3/16 1 29-1/2aPitch must be measured at right angles to the direction of corrugations. A tolerance of ±1/2inch on seam pitch is allowable.

66-1.02E(2)(c)(ii) Fabrication by Continuous Lock SeamYou may use pipes fabricated with a continuous helical lock seam extending from end to end of eachlength for full circle and equivalent pipe arch sizes. Fabrication must comply with AASHTO M 36, exceptthe profile of the sheet on at least 1 side of the lock seam and adjacent to the 180-degree fold must havea minimum retaining offset of 1/2 the sheet thickness as defined under California Test 662.

Sampling and testing for continuous quality control of lock seams must comply with California Test 662.

66-1.02E(2)(c)(iii) Fabrication by Continuous Welded SeamYou may use pipes fabricated with a continuous helical welded seam parallel to the corrugations for fullcircle and equivalent pipe arch sizes. Control the welding process so that the combined width of the weldand adjacent spelter or aluminum coating burned by the welding does not exceed 3 times the metalthickness.

If the spelter is damaged by the welding outside the specified area, repair the weld and damaged spelteradjacent to the weld under section 75-1.05.

If the metalizing is applied immediately in a continuous operation following the resistance welding, apply acoating of aluminum to the welded area of aluminum-coated pipe using the metalizing process underAWS C2.2, except surface cleaning will not be required.

Quality control testing of the welded seam must comply with California Test 665.

66-1.02E(3) End FinishHelically corrugated steel pipe ends may be rerolled to form annular corrugations extending at least 2corrugations from the pipe end or to form an upturned flange with or without reformed annularcorrugations. The diameter of the reformed ends must not exceed that of the pipe barrel by more than thedepth of the corrugation. All types of pipe ends, whether rerolled or not, must be matched in a joint so thatthe maximum difference in diameter of the abutting pipe ends is 1/2 inch.

If the ends of helically corrugated steel lock seam pipes have been rerolled, the lock seam in the rerolledend must not contain visible cracks in the base metal and the tensile strength of the lock seam must be atleast 60 percent of the tensile strength required for the remainder of the pipe. This requirement does notapply to the lock seam located within a flange formed in rerolling. The rerolled ends of the pipe andflanges must exhibit good workmanship and must not have open lock seams.

If corrugated steel pipe is rerolled for coupling with a wing channel coupling or a channel coupling band,the maximum distance from any point on the end of the pipe to the plane, normal to pipe axis and passingthrough the outermost portion of the pipe end, must not exceed 1/2 the width of the channel minus thethickness of the pipe metal. The difference between the minimum and maximum flange diameter must notexceed 1/2 inch.

Fabricate pipes so that they can be joined effectively with the described standard coupling bands.


REVISION 0


66-1.02E(4) Damaged GalvanizingRepair damaged galvanized surfaces under section 75-1.05.

If you burn the galvanized surfaces by welding, thoroughly clean all the surfaces of the weldedconnections by wire brushing and remove all traces of the welding flux and loose or cracked galvanizingbefore repair.

66-1.02E(5) Damaged Aluminum CoatingsRepair damaged aluminum coatings under section 75-1.05.

66-1.02E(6) Corrugated Steel Pipe SiphonsThe thickness of siphons must be the described thickness. If coating is required, coated pipes mustcomply with section 66-1.02C.

Order pipes for siphons in lengths that will keep the number of field connections to a minimum.

If soldering is required, the outside seams of pipe fabricated by riveting, or continuous helical lock seammust be soldered, the solder being sweated into the joints. If the pipe is fabricated by riveting, rivets onthe circumferential seams must be spaced at approximately 2-1/2-inch centers with a maximum spacingof 3 inches. If the pipe is fabricated by a continuous helical welded seam, soldering is not required.

66-1.02F Corrugated Aluminum Pipe66-1.02F(1) GeneralCorrugated aluminum materials must comply with AASHTO M 196 and AASHTO M 197.

66-1.02F(2) Fabrication66-1.02F(2)(a) GeneralCorrugated aluminum pipe must be fabricated by riveting or with a continuous helical lock seamparalleling the corrugations. Annular or helically corrugated pipe must be fabricated from sheets having 2-2/3-by-1/2-inch or 3-by-1-inch corrugations.

66-1.02F(2)(b) Fabrication by RivetingPipes fabricated by riveting must be lap joint construction with annular corrugations. Fabrication mustcomply with AASHTO M 196.

66-1.02F(2)(c) Fabrication by Continuous Helical Lock SeamFor full circle and equivalent pipe arch sizes, you may install pipes fabricated with a continuous helicallock seam extending from end-to-end of each length. Fabrication must comply with AASHTO M 196,except the sheet profile on at least 1 side of the lock seam and adjacent to the 180 degree fold must havea minimum retaining offset of 1/2 the sheet thickness as defined under California Test 662.

Sampling and testing for quality control of continuous lock seams must comply with California Test 662.

66-1.02F(3) End FinishHelically corrugated aluminum pipe ends may be rerolled to form annular corrugations extending at least2 corrugations from the pipe end. The diameter of the reformed ends must not exceed the diameter of thepipe barrel by more than the corrugation depth. All types of pipe ends, whether rerolled or not, must bematched in a joint so that the maximum difference in diameter of the abutting pipe ends is 1/2 inch.

If the ends of helically corrugated aluminum lock seam pipes have been rerolled, the lock seam in thererolled end must not contain visible cracks in the base metal and the tensile strength of the lock seammust be at least 60 percent of the tensile strength required for the remainder of the pipe. The rerolled pipeends must exhibit good workmanship and must not have open lock seams.

Pipes must be fabricated so that they can be joined effectively with the described standard couplingbands.


REVISION 0


66-1.03 CONSTRUCTIONExcavate a pipe trench to the lines and grades established by the Engineer. Grade and prepare thetrench bottom to provide a firm and uniform bearing throughout the entire pipe length.

Lay annular corrugated pipe in a trench with:

1. Outside laps of circumferential joints upgrade2. Longitudinal laps positioned other than in the invert3. Separate sections spaced not more than 1-1/2 inches apart and then firmly joined together

Lay helical corrugated pipe in a trench with separate sections spaced not more than 1-1/2 inches apartand then firmly jointed together with corrugations in alignment.

Corrugations or projections on the coupler must properly engage the corrugations of the pipe sectionbefore bolts are tightened.

Connect new corrugated metal pipe to new or existing drainage facilities as shown. If concrete collars ortee connections are required, construct the collars or tee connections with minor concrete. Reinforcementmust comply with section 52.

Wherever pipes are connected to inlet and outlet structures, place the ends of the pipes flush or cut themoff flush with the structure face.

66-2 SLOTTED CORRUGATED STEEL PIPE66-2.01 GENERALSection 66-2 includes specifications for fabricating and constructing slotted corrugated steel pipe.

66-2.02 MATERIALSSlotted corrugated steel pipe must be grate-slot type as shown.

Grate assemblies for slotted corrugated steel pipe must comply with section 75-1.02, but may befabricated from any of the materials under section 75-1.02 for steel bars, plates and shapes. Any damageto the galvanized surface of the pipe at the toe of the grate assembly fillet weld connection to the pipemust be repaired under section 75-1.05.

Where a heel guard is shown, the heel guard must be expanded metal and must comply with ASTMF1267, Type II, Class 2, and Grade B. Galvanizing must comply with section 75-1.05.

Coupling bands for slotted corrugated steel pipe must be galvanized or coated as shown.

Join slotted corrugated steel pipe with coupling bands as shown. Joints must be watertight.

If you use a channel coupling band, place a 3/8-inch-thick closed-cell sponge neoprene gasket or butylrubber joint sealant in the channel interior for its full width.

If you use a modified hugger band, place a butyl rubber joint sealant between the coupling band and theperiphery of the pipe. The butyl rubber joint sealant material must:

1. Be an extruded strip or bead compounded from a nondrying, nontoxic, synthetic resin base with butylrubber and inorganic extenders and be 100 percent solid material with no shrinkage

2. Be furnished in 5/8-by-1-inch strips or 1-inch-diameter beads on 1-inch-wide release paper andwound into rolls

3. Have enough adhesion so that the strip or bead will adhere to the galvanized steel and be softenough to allow cold flow if compressed during connection of the pipe sections

4. Not flow or sag at temperatures up to 180 degrees F or become brittle, crack, or lose adhesion at -30degrees F

5. Contain no migrating components that could leach out or produce a chemical reaction with thegalvanized steel


REVISION 0


You may use an alternative joint sealant or sealing method for slotted corrugated steel pipe to provide awatertight joint if authorized.

66-2.03 CONSTRUCTIONDo not start installation of slotted corrugated steel pipe until after paving of the traffic lanes adjacent to thepipe have been completed at the locations where the pipe is to be placed.

Cover pipe slots with a heavy duty tape or other authorized covering during backfilling and pavingactivities to prevent material from entering the slots.

Place cement treated structure backfill for slotted corrugated steel pipe under the details shown andsection 19-3.02E(3) for soil cement beddings. Cover the completed cement treated structure backfill witha curing seal of asphaltic emulsion, Grade SS1 or CSS1.

Do not place loads on the cement treated structure backfill within 16 hours after placement.

67 STRUCTURAL PLATE CULVERTSNot Used

68 SUBSURFACE DRAINS68-1 GENERAL

68-1.01 GENERALSection 68-1 includes general specifications for constructing subsurface drains.

Submit a certificate of compliance for each type of subsurface drain involved.


68-1.02B Protective CoatingIf described as coated, subsurface drains must be protected with a coating under section 66-1.02C.

Repair damaged coatings under section 66-1.02C.


68-1.03B Filter FabricRemove loose or extraneous material and sharp objects immediately before placing filter fabric.

The subgrade and trench to receive the filter fabric must comply with the compaction and elevationtolerance specified for the material involved.

Handle and place filter fabric under the manufacturer's instructions.

Align and place filter fabric without wrinkles.

Overlap adjacent roll ends of filter fabric at least 18 inches. The preceding roll must overlap the followingroll in the direction that the permeable material is being spread.

Completely replace torn or punctured sections damaged during placement or repair by placing a piece offilter fabric that is large enough to cover the damaged area and comply with the overlap specified.

Cover filter fabric with the thickness of overlying material shown within 72 hours of placing the fabric.

68-2 UNDERDRAINSNot Used


REVISION 0


68-3 HORIZONTAL DRAINSNot Used

68-4 EDGE DRAINS68-4.01 GENERALSection 68-4 includes specifications for constructing plastic pipe edge drains and edge drain outlets.

Cross drain interceptors at structure approaches, at end anchors or pressure relief joints, and atpavement terminals joining existing pavements are considered edge drains.


68-4.02B Pipe and Pipe FittingsPipe installed in trenches to be backfilled with asphalt treated permeable material must be PVC 90°Celectric plastic conduit, EPC-40 or EPC-80, and must comply with NEMA TC 2.

All other edge drain pipe and edge drain outlets, vents, and cleanouts must be one of the following:

1. PVC 90°C electric plastic conduit, EPC-40 or EPC-80, and must comply with NEMA TC 2.2. PVC plastic pipe, schedule 40 or schedule 80, and must comply with ASTM D1785. At your option,

the type, grade, and design stress designation of the pipe may be 1120, 1220, 2120, 2116, 2112, or2110 as specified in ASTM D1785.

Pipe must be straight end or bell end. Bell end sockets must comply with ASTM D2672 except formarking.

Pipe shown as slotted must have 3 rows of slots in the pipe. The rows must be in the longitudinaldirection of the pipe and the slots must be cut in the circumferential direction of the pipe. The 3 rows mustbe spaced equally around the circumference of the pipe. Each row must have 22 ± 1 uniformly spacedslots per linear foot of pipe. The slots must be 0.045 to 0.065 inch wide and of such length as to provideat least 2.00 square inches of slot opening per linear foot of pipe. Other suitable configurations of slotsthat provide drainage equal to or better than the above slot requirements may be used if authorized.

Fittings for PVC 90°C electric plastic conduit must comply with NEMA TC 3, and fittings for PVC plasticpipe must be socket-type fittings under ASTM D2467 for schedule 80 pipe and ASTM D2466 for schedule40 pipe. Y-fittings must be shop fabricated from pipe as specified for the type of edge drain pipe installed.The fitting must provide an unobstructed passageway through both legs of the Y-fitting.

68-4.02C Treated Permeable MaterialAt your option, permeable material for edge drains must be asphalt treated permeable material or cementtreated permeable material complying with section 29-1.02 for treated permeable bases.

Store, proportion, and mix treated permeable material under section 29-1.03C.

68-4.02D Filter FabricFilter fabric must comply with section 88-1.02B.

68-4.02E MiscellaneousConcrete for splash pads must be constructed of minor concrete, except the concrete must contain atleast 470 pounds of cementitious material per cubic yard.

Mortar placed where edge drain outlets and vents connect to drainage pipe and existing drainage inletsmust comply with section 51-1.

Expansion type pressure plugs for cleanouts must seat firmly against the pipe lip and be one of thefollowing:


REVISION 0


1. Expandable plugs manufactured from neoprene under section 51-2.04 with commercial qualitystainless steel bolts and 2 hex nuts

2. Commercial quality expandable duct plugs consisting of reinforced polypropylene rigid threaded plugwith a commercial quality thermoplastic rubber sealing ring

Aggregate base for backfilling trenches in existing paved areas must comply with the materialsspecifications for Class 2 aggregate base, 3/4-inch-maximum grading, under section 26-1.02B.

HMA for backfilling trenches must comply with section 39-1.15.

Outlet and vent covers must be commercial quality galvanized metal screens or grates approximately 1/2-inch mesh with PVC slip joint nut fittings.

68-4.02F–68-4.02H Not Used68-4.03 CONSTRUCTIONBefore excavating trenches for the installation of edge drains, outlets, vents, and cleanouts in existingpaved areas, cut the outline of the paved areas to be removed to a neat line to a minimum depth of 2inches with a power-driven saw or a wheel type rock cutting excavator. Cuts along the joint betweenexisting asphalt concrete and existing concrete pavement are not required.

Remove concrete deposits that could occur along the lower edge of the concrete pavement in Type 1installations.

Join pipe and fittings with commercial quality solvent cement and primer specifically manufactured for usewith rigid PVC plastic pipe and fittings. The solvent cement and primer must be made by the samemanufacturer. The color of the primer must contrast with the color of the pipe and fittings. Apply thesolvent cement and primer under the manufacturer's instructions.

Spread treated permeable material when the atmospheric temperature is above 40 degrees F.

You may spread the treated permeable material in 1 or more layers.

Where edge drains are to be installed adjacent to asphalt treated permeable base, you may spread thelower 6 inches of asphalt treated permeable material in a separate operation, then spread the upperportion of the asphalt treated permeable material with the adjacent asphalt treated permeable base.

Place asphalt treated permeable material at a temperature of not less than 180 degrees F or more than230 degrees F, except the temperature of asphalt treated permeable material spread with asphalt treatedpermeable base must comply with section 29 for spreading asphalt treated permeable base.

Compact asphalt treated permeable material spread with adjacent asphalt treated permeable base withthe adjacent base and in the same way specified in section 29 for compacting the base. Compact allother layers of treated permeable material with a vibrating shoe-type compactor connected to thespreading device. The vibrating shoe-type compactor must be in operation when the material is beingspread in the trench and must be turned off when the material is not being spread.

Cure cement treated permeable material that is not covered with HMA within 12 hours after compaction ofthe permeable material by sprinkling the material with a fine spray of water every 4 hours during daylighthours or by covering the material with a white polyethylene sheet not less than 6 mils thick. Start thecuring requirements at 7:00 a.m. on the morning following compaction of the cement treated permeablematerial and continue for the next 72 hours or until the material is covered with HMA, whichever is less.Do not spray the cement treated permeable material with water during the first 12 hours after compacting.You may cover the cement treated permeable material with the polyethylene sheet during the first 12hours or before the start of the curing period.

Backfill and compact trenches in existing embankment areas with native material.

Aggregate base backfill must be spread and compacted by methods that produce a uniform base, firmlycompacted and free from pockets of coarse or fine material.


REVISION 0


Place Type A pavement markers as shown and under section 85 of the Standard Specifications on pavedshoulders or dikes at outlet, vent, and cleanout locations where authorized. The waiting period for placingpavement markers on new HMA surfacing does not apply.

Clean edge drain outlets, vents, and cleanout pipes when installed and remove obstructions afterinstallation. Use a high-pressure, flexible hose with a nominal 1-inch diameter nozzle containing flushingand propelling jets. Insert the hose into each edge drain outlet, vent, and cleanout pipe and push itthrough the pipe with a minimum 1,000 psig water pressure so that the entire edge drain system ispenetrated by the flushing nozzle. Replace pipes found to be plugged, including replacement of treatedpermeable material, surfacing, and backfill materials.

Install outlet and vent covers at the end of each outlet pipe and vent pipe.

Dispose of surplus excavated material.

68-5 PERMEABLE MATERIAL BLANKETNot Used

68-6 DRAINAGE WICKNot Used

68-7 GEOCOMPOSITE DRAIN SYSTEMS68-7.01 GENERAL68-7.01A SummarySection 68-7 includes specifications for constructing geocomposite drain systems.

Structure approach drainage system consists of geocomposite drain, filter fabric, plastic pipe, treatedpermeable base, and drainage pads.

Geocomposite drain includes filter fabric and plastic pipe.


68-7.01C SubmittalsSubmit a certificate of compliance for the geocomposite drain certifying that the drain produces thespecified flow rate. The certificate must be accompanied by a flow capability graph for the geocompositedrain showing flow rates and the externally applied pressures and hydraulic gradients. Include verificationby an authorized laboratory for the flow capability graph.

68-7.02 MATERIALS68-7.02A GeneralFilter fabric must be Class A.

68-7.02B Geocomposite DrainGeocomposite drain must comply with the specifications for geocomposite wall drain in section 88-1.02C.

68-7.02C Plastic PipePlastic pipe must comply with the specifications for pipe for edge drains and edge drain outlets in section68-4.

68-7.02D Drainage PadsDrainage pads must be constructed of minor concrete.

68-7.02E Treated Permeable BaseTreated permeable base to be placed around slotted plastic pipe at the bottom of geocomposite drainsmust comply with section 29.


REVISION 0


If asphalt treated permeable base is used, place the base material at a temperature of not less than 180degrees F or more than 230 degrees F.

68-7.03 CONSTRUCTIONInstall the geocomposite drain with the drainage void and the filter fabric facing the embankment. Thefabric facing the embankment side must overlap at least 3 inches at all joints and wrap around theexterior edges at least 3 inches beyond the exterior edge. If additional fabric is needed to provide overlapat joints and wraparound at edges, the added fabric must overlap at least 6 inches and be attached to thefabric on the geocomposite drain.

Place core material manufactured from impermeable plastic sheeting having nonconnecting corrugationswith the corrugations approximately perpendicular to the drainage collection system.

If the fabric on the geocomposite drain is torn or punctured, replace the damaged section completely orrepair it by placing a piece of fabric that is large enough to cover the damaged area and provide at least a6-inch overlap.

69 OVERSIDE DRAINSNot Used

70 MISCELLANEOUS DRAINAGE FACILITIES71 NOT USED

Not Used

DIVISION VIII MISCELLANEOUS CONSTRUCTION72 SLOPE PROTECTION

Not Used

73 CONCRETE CURBS AND SIDEWALKSNot Used

74 PUMPING EQUIPMENT AND CONTROLSNot Used

75 MISCELLANEOUS METAL75-1.01 GENERAL75-1.01A SummarySection 75 includes specifications for fabricating and installing miscellaneous metal materials.

75-1.01B Quality Control and AssuranceMiscellaneous metal materials are inspected at the fabrication site. Notify the Engineer:

1. When materials have been delivered to the fabrication site2. At least 10 days before starting fabrication

75-1.02 MISCELLANEOUS IRON AND STEELNot Used

75-1.03 MISCELLANEOUS BRIDGE METAL75-1.03A GeneralMiscellaneous bridge metal must comply with section 75-1.02.

Miscellaneous bridge metal consists of:


REVISION 0


1. Structural steel and cast steel portions of bearing plates, bars, rockers, assemblies, and otherexpansion or fixed bearing devices in concrete structures

2. Equalizing bolts and expansion joint armor in concrete structures3. Expansion joint armor in steel structures4. Manhole frames and covers, frames and grates, ladder rungs, guard posts, and access door

assemblies5. Deck drains, area drains, retaining wall drains, and drainage piping not included in bridge deck

drainage system6. Checkered plate and cap screw for walkway cover

Produce the parts shown in the table below from the corresponding materials shown:

Miscellaneous Metal PartsPart Material

Bearing assemblies ASTM A 36/A36MAccess opening covers Commercial-quality sheet steelAccess doors Galvanized sheet steel complying with ASTM A 653/A 653M, Coating

Designation G210 [Z600]Springs for deck draingrating latchesa

Commercial-quality, stainless steel spring wire containing a nominalcomposition of 18% chromium and 8% nickel

Pipe bends Commercial-quality tube bends or fabricated bends of equalsmoothness. Do not use miter-joint bends.

Metal parts of anchoragedevices except ironcastings for CIP inserts

Steel or stainless steel

Iron castings for CIP inserts Malleable iron or ductile ironaTest spring latches and other mechanical devices before delivery to the job site; they must operatesmoothly and properly.

Cast steel and cast iron must comply with section 55.

Transition fittings between pipes of different diameters must be:

1. Smooth and uniform, without sags, projections, or offsets2. At least 4 inches in length for each 1-inch reduction in pipe diameter.

Sealing compound for caulking and adhesive sealing must be polysulfide or polyurethane complying withASTM C 920, Type S, Grade NS, Class 25, Use O.

75-1.03B Bolted and Threaded Bar ConnectionsHS bolted connections must comply with the specifications for HS steel fasteners and bolted connectionsin section 55.

Equalizing bolts must be bolts or threaded bars. Threaded bars shown as prestressing steel must complywith the specifications for plain bars in ASTM A 722/A 722M, including supplementary requirements. Nutsmust comply with the 1st and 2nd paragraphs of section 50-1.03B(2)(c).

Where cleaning is described, clean nuts, bolts, threaded bars, and plate washers under SSPC-SP 6 orSSPC-SP 2. Abrasives used for blast cleaning must comply with section 59-1.02B.

Surfaces blast cleaned under SSPC-SP 6 must have a dense, uniform, angular anchor pattern of at least1.5 mils when measured under ASTM D 4417. Paint blast-cleaned surfaces the same day blast cleaningis performed unless otherwise authorized.

Reclean surfaces that rust or become contaminated before paint is applied.


REVISION 0


Paint surfaces except threads engaged by nuts with 2 applications of organic zinc-rich primer. Do not useaerosol cans. Apply the 2nd application to the nuts and threads after installation. Organic zinc-rich primermust be on the Authorized Material List

Thread locking systems must be on the Authorized Material List for anaerobic thread locking systems andmust comply with the requirements thereon.

75-1.03C Anchorage Devices75-1.03C(1) GeneralConcrete anchorage devices must be mechanical expansion anchors or resin capsule anchors installed indrilled holes or CIP concrete inserts.

Concrete anchorage devices must be on the Authorized Material List.

Submit a certificate of compliance for anchorage devices.

An anchorage device must be a complete system, including threaded studs, hex nuts, and cut washers.Thread dimensions for externally threaded anchorage devices before zinc coating must comply withASME B1.1 having Class 2A tolerances or ASME B1.13M having Grade 6g tolerances. Threaddimensions for internally threaded concrete anchorage devices must comply with ASTM A 563.

Except for mechanical expansion anchors and iron castings for CIP inserts, metal parts of anchoragedevices must be hot-dip or mechanically galvanized.

Mechanical expansion anchors must be (1) hot-dip or mechanically galvanized, (2) made from stainlesssteel, or (3) coated with electrodeposited zinc complying with ASTM B 663.

Iron castings must be mechanically galvanized.

Install mechanical expansion anchors, resin capsule anchors, and CIP inserts under the manufacturer'sinstructions.

If the manufacturer's instructions do not include torque requirements, tighten nuts used to attachequipment or fixtures to anchorage devices to the installation torque values shown in the following table:

Torque RequirementsStud

diameter(inches)

Installation torque values (ft-lb)Shell-type mechanical

expansion anchorsIntegral-stud-type mechanical

expansion anchorsResin capsule anchors

and CIP inserts1-1/4 -- -- 400

1 -- -- 2307/8 -- -- 1753/4 80 175 1505/8 35 90 751/2 22 50 303/8 11 25 181/4 4 7 --

Install concrete anchorage devices such that the attached equipment or fixtures bear firmly against theconcrete.

75-1.03C(2) Mechanical Expansion AnchorsMechanical expansion anchors must be the integral stud type or the shell type with internal threads andan independent stud. Do not use self-drilling mechanical expansion anchors.

When tested under California Test 681, mechanical expansion anchors must withstand the application ofa sustained tension test load of at least the values shown in the following table for at least 48 hours with amovement of at most 0.035 inch:


REVISION 0


Mechanical Expansion Anchor Sustained Tension Test LoadStud diameter

(inches)Sustained tension test load

(pounds)3/4a 5,0005/8 4,1001/2 3,2003/8 2,1001/4 1,000

aMaximum stud diameter allowed for mechanical expansionanchors

Install shell-type mechanical expansion anchors such that the top surface of the anchor body remains 1/2to 1 inch below the concrete surface after expansion. After installation of shell-type mechanical expansionanchors and before mounting to equipment or fixture, demonstrate to the Engineer that the expansionanchors are firmly seated within these tolerances.

75-1.03C(3) Resin Capsule AnchorsWhen tested under California Test 681, resin capsule anchors must withstand the application of asustained tension test load of at least the values shown in the following table for at least 48 hours with amovement of at most 0.010 inch:

Resin Capsule Anchor Sustained Tension Test LoadStud diameter

(inches)Sustained tension test load

(pounds)1-1/4 31,000

1 17,9007/8 14,4003/4 5,0005/8 4,1001/2 3,2003/8 2,1001/4 1,000

75-1.03C(4) Cast-In-Place Concrete InsertsCIP concrete inserts must be ferrule loop or cast iron.

When tested under California Test 682, CIP inserts must withstand the minimum ultimate test loadsshown in the following table:

CIP Insert Sustained Tension Test LoadStud diameter

(inches)Ultimate tensile load

(pounds)1-1/4 25,0001-1/8 19,800

1 16,0007/8 11,6003/4 7,2005/8 6,6001/2 4,200

75-1.03D Bridge Deck Drainage System75-1.03D(1) GeneralBridge deck drainage system consists of:


REVISION 0


1. Steel Bars2. Steel Pipe3. Expansion Couplers4. Pipe Casing5. Hanger rod and strap

Securely cover deck drain grates and other grating openings to prevent intrusion of debris until after finalcleanup of the deck and drainage areas.

After final cleanup of the deck and drainage areas, test each drain pipe and facility except short free fallpipes in the Engineer's presence by discharging 100 gallons of water into the drain. The test mustdemonstrate the proper operation of the drain pipe and facility. If the test indicates obstructions in thepipe, clear the pipe and repeat the test until the drain pipe and facility are unobstructed.

75-1.03D(2) Pipe Connections and JointsSelf-tapping screws for sleeve connections must:

1. Be stainless steel with hex-heads2. Be installed in holes drilled to fit the screws3. Comply with ASTM A 276, Type 304, for a project in a non-freeze-thaw area4. Comply with ASTM A 276, Type 316, for a project in a freeze-thaw area

Drain pipe joints must be watertight, smooth, and free from projections or offsets over 1/16 inch on theinside. Mechanical couplings in piping must be gasketed short sleeve type consisting of:

1. Mild steel middle ring with pipe stop2. 2 rubber compound wedge section ring gaskets3. 2 mild steel follower rings4. Mild steel bolts to compress the gaskets

Provide a transition section where a pipe under a walkway or other improved area must be of a smallerdiameter than the downdrain pipe.

Couplings used to connect PVC or fiberglass pipe to steel must be threaded or flanged. For PVC orfiberglass pipe, do not use the sleeve connections shown.

75-1.03D(3) Fiberglass Pipes and FittingsYou may use fiberglass pipes and fittings with the same diameters and minimum bend radii as showninstead of welded pipe.

Submit a certificate of compliance for fiberglass pipe and fittings; include laboratory test results.

Fiberglass pipe and fittings must:

1. Comply with ASTM D 29962. Have a minimum short-term rupture strength of 30,000 psi

For joining pipe and fittings, use the adhesive type recommended by the manufacturer.

Fiberglass pipe not enclosed in a box girder cell or encased in concrete must be made from UV-resistantresin pigmented with concrete-gray color or be coated with a concrete-gray resin-rich exterior coating. Donot use paint.

Fiberglass pipe with UV protection must withstand a at least 2,500 hours of accelerated weathering whentested under ASTM G 154 with UVB-313 lamps. The resting cycle must be 4 hours of UV exposure at 140degrees F and then 4 hours of condensate exposure at 120 degrees F. After testing, the pipe surfacemust show no fiber exposure, crazing, or checking and only slight chalking or color change.

Support spacing for fiberglass pipe must be the same as shown for welded steel pipe. Each pipe supportmust have a width of at least 1-1/2 inches.


REVISION 0


75-1.03D(4) PVC Pipes and FittingsFor drainage pipe NPS 8 or smaller encased in concrete or enclosed in a box girder cell and exposed forat most 20 feet within the cell, you may use PVC pipe and fittings with the same diameters and minimumbend radii as shown instead of welded pipe.

The PVC pipe and fittings must be Schedule 40, complying with ASTM D 1785. Pipe support spacingmust be at most 6 feet.

75-1.03E Bridge Joint Restrainers75-1.03E(1) GeneralBridge joint restrainers include various combinations of the following: structural steel parts, bolts, bearingplates, cable drum units, pipe sleeves, PVC pipe, elastomeric pads, expansion joint filler, expandedneoprene, expanded polystyrene, sheet neoprene, hardboard, and incidentals.

Place new concrete adjacent to restrainers before installing restrainers.

Where removing and replacing restrainers, remove at most 50 percent of the restrainers at any joint andreplace them with an equal proportion of new restrainers before subsequent removal activities. Performall removal and replacement symmetrically about the centerline of the existing bridge.

75-1.03E(2) Cable Type75-1.03E(2)(a) GeneralCable-type restrainers consist of cables, swaged fittings, studs, nuts, cable yield indicators, disc springs,and if shown, turnbuckles.

You are responsible for determining the required lengths of the cable-type restrainers.

Cable restrainers must have corrosion protection.

Submit at the manufacturer's plant:

1. 1 cable-type restrainer test sample for each 200 restrainers or fraction thereof produced. The samplerestrainer must consist of a cable fitted with a swaged fitting and right hand thread stud at both endsand must be 3 feet in total length.

2. 1 turnbuckle fitted with an 8-inch stud at each end for each 200 turnbuckles or fraction thereof.3. Greater of 1 percent or 8 of the cable yield indicators produced from each mill heat.4. 2 disc springs of each size produced from each mill heat.

Submit 2 certified copies of mill test reports of each manufactured length of cable.

Submit 2 certified copies of the mill test and heat treating reports of each heat of bars used for cable yieldindicators.

75-1.03E(2)(b) MaterialsEach swaged fitting, turnbuckle, stud, and nut assembly must develop the specified breaking strength ofthe cable.

Cables must be galvanized, 3/4-inch preformed, 6 by 19, wire strand core or independent wire rope core,complying with Federal Specification RR-W-410, right regular lay, manufactured of improved plow steelwith a minimum breaking strength of 23 tons.

Securely wrap each free end of restrainer-unit cables to prevent separation.

Each swaged fitting must:

1. Be machined from hot-rolled steel bars complying with AISI C-10352. Be annealed, suitable for cold swaging3. Have a hole drilled through the head to accommodate the locking pin4. Have the manufacturer's identifying mark stamped on the body


REVISION 0


The locking pin must be a 1/4-inch-diameter, zinc plated steel spring pin and keep the stud in properposition.

Each stud must comply with ASTM A 449 after galvanizing. Before galvanizing, mill a 3/8-inch slot for thelocking pin in the stud end.

Nuts must comply with ASTM A 563, including appendix X1, except lubrication is not required.

Each cable yield indicator must:

1. Be machined from hot-rolled steel bars complying with AISI C-10352. Be annealed, suitable for cold swaging3. Have the heat number and manufacturer's identifying mark stamped on the end surface

Machine the wall of the reduced section of the cable yield indicator so that the indicator yields at a loadfrom 36,000 to 38,000 lb when tested in compression along the major axis at a test speed of at most 1/2inch/minute.

Disc springs must be made from steel complying with ASTM A 684/A 684M, Grade 1075. Do notgalvanize disc springs; clean and paint them with a paint recommended by the manufacturer and colorshown.

Turnbuckles must be steel pipe type. Pulls for turnbuckles must consist of a swaged fitting and studassembly.

Steel parts must comply with ASTM A 36/ A36M or A 576, Grade 1030, (AISI 1030) and must not berimmed or capped steel.

You may drill holes in steel parts after galvanizing if you repair the holes as specified for repairingdamaged galvanized surfaces in section 75-1.05.

The minimum size of fillet welds must comply with AWS D1.1 except as follows:

Minimum Fillet Weld SizesBase metal

thickness of thickerpart joined (T)

(inches)

Minimum size offillet weld(inches)

3/4 < T 1-1/2 5/161-1/2 < T 2-1/4 3/8

2-1/4 < T 6 1/26 < T 5/8

Pipe sleeves must be commercial-quality welded steel pipe.

Concrete for filling cable drum units must either (1) comply with the specifications for minor concrete or(2) be a concrete mix with a 3/8-inch maximum combined aggregate grading and at least 675 pounds ofcementitious material per cubic yard.

Elastomeric bearing pads must comply with section 51-3.02 except pads may consist of only elastomerand laminated reinforcement is not required.

PVC must be commercial quality.

Bond breaker on PVC pipe must be a mortar-tight wrapping of plastic or rubber sheet at least 0.010 inchthick.

Expanded polystyrene and hardboard must comply with section 51-2.01B(1).


REVISION 0


Neoprene sheets must comply with the specifications for neoprene in section 51-2.04. The sheets mustbe smooth, free from pinholes and surface blemishes, and show no evidence of delamination.

Closed-cell expanded neoprene material must be commercial quality and comply with the stiffnessrequirements in ASTM D 1056 for Class SC, Grade SCE43 material or firmer.

Ship cable-type restrainers as complete units.

75-1.03E(2)(c) InstallationNotify the Engineer at least 2 days before tightening and setting cable-type restrainer units.

Repair existing structural steel paint areas that you damage and holes you drill through existing steelmembers as specified for repairing damaged galvanized surfaces in section 75-1.05.

If paint removal or welding at connections to existing steel is not described at restrainer locations, washloose dirt and dust from existing contact surfaces of HS bolted connections without disturbing the existingpaint. Clean and paint existing contact surfaces of HS bolted connections that contain rust, loose paint, orother foreign substances except dirt and dust;

75-1.03E(2)(d) Corrosion Protection75-1.03E(2)(d)(i) GeneralSection 75-1.03E(2)(d)(i) applies if corrosion protection on cable-type restrainers is specified in thesespecifications.

Submit a test sample of grease from the lot to be used and test results at least 40 days before use.

For the locknuts, submit a certificate of compliance with a copy of each required test report.

75-1.03E(2)(d)(ii) MaterialsThe corrosion protection system must be on the Authorized Material List and comply with therequirements thereon.

The grease must comply with the corrosion-inhibiting grease specifications in section 46-2.02D.

The sheathing must have:

1. Density of 940 kg/m3 to 960 kg/m3 as measured under ASTM D 792, Test Method B2. Minimum wall thickness of 80 mils

The sheathing must be:

1. Sufficiently strong to prevent damage during construction2. Watertight3. Chemically stable without embrittlement or softening4. Nonreactive with concrete, steel, or corrosion inhibiting grease

The Department rejects burned or damaged HDPE sheathing.

The nuts must be mechanically zinc-coated nylon insert locknuts complying with ASTM A 536, Grade DH,and ASME B18.22.2 except that the thickness must be greater than that specified in ASME B18.2.2. Thenuts must maintain complete locking effectiveness at 100 percent relative humidity. Do not use threadlocking systems. The mechanical and thermal properties of the nylon resin used in the locknut insert musthave the values shown in the following table:


REVISION 0


Nylon Insert RequirementsProperty Test method Value

Mechanical:Tensile strength ASTM D 638 12,000 psi minTensile strength at yield ASTM D 638 12,000 psi minElongation at yield ASTM D 638 5 percent maxElongation at break ASTM D 638 60 percent maxFlexural modulus ASTM D 790 410 ksiIzod impact ASTM D 256 53 J/m

Thermal:Heat deflection temperature at 66 psi ASTM D 648 210 °C at 264 psi ASTM D 648 65 °CMelting point ASTM D 3418 260 °C

The pigment composition and physical properties of the penetrant must have the values shown in thefollowing table:

Penetrant Pigment Composition and Property RequirementsPigment composition or property Test method Value

Total pigment content ASTM D 2371 24–28 percentPigment component:

Synthetic red iron oxide ASTM D 3721 19–23 percentZinc hydroxy phosphite ASTM D 4462 33–37 percentBarium sulfate ASTM D 602 40–48 percent

Nonvolatile content ASTM D 2369 60 percent minConsistency, KU ASTM D 562 50–75Density ASTM D 1475 1.018 g/mLDrying time, dry to recoat, 4 mils wet film ASTM D 1640 2–4 hoursFlash point ASTM D 3278 40 °C minSalt fog performance, 1–2 mils dry film onabrasive blast cleaned panel under SSPC-SP 5,white metal blast cleaning

ASTM B 117 500 hours, no rust or creepage atscribe

The penetrant vehicle must consist of 75 to 79 percent overbased crystalline calcium sulphonate alkydresin and 21 to 25 percent driers, UV absorbers, and aliphatic hydrocarbons. The properties of the resinsolution must have the values shown in the following table:

Resin Solution Property RequirementsProperty Test method Value

Density ASTM D 1475 0.935 g/mLFlash point ASTM D 3278 40 °C minNonvolatile content ASTM D 2369 70 percent minViscosity ASTM D 2196, no. 6 spindle at 25 °C, 10 rpm 9,000 cP min

The pigment composition and physical properties of the finish coat must have the values shown in thefollowing table:


REVISION 0


Finish Coat Pigment Composition and Property RequirementsPigment composition or property Test method Value

Total pigment content ASTM D 2371 22–28 percentPigment component:

Titanium dioxide ASTM D 476,Type III or IV

40–43 percent

Carbon black ASTM D 561 0.04–1.00 percentZinc hydroxy phosphite ASTM D 4462 28–32 percentBarium sulfate ASTM D 602 26–30 percent

Nonvolatile content ASTM D 2369 70 percent minConsistency, KU ASTM D 562 90–120Density ASTM D 1475 1.139 g/mLDrying time, dry to recoat, 4 mils wet film ASTM D 1640

Dust free 1–4 hoursTack free 5–12 hoursDry hard 24–48 hours

Flash point ASTM D 3278 40 °CSag resistance ASTM D 4400 16 mils minSalt fog performance, 100 µm dry film on SSPC-SP 5blasted cold-rolled steel panel

ASTM B 117 1,000 hours, no more than1 percent undercutting,blistering, or peeling

The finish coat vehicle must consist of 77 to 81 percent overbased crystalline calcium sulphonate alkydresin, 12 to 16 percent modified alkyd, and 7 to 9 percent driers, UV absorbers, and aliphatichydrocarbons. The properties of the resin solution must have the values shown in the table titled "ResinSolution Property Requirements" above.

The finish coat must match color no. 26373 of FED-STD-595.

75-1.03E(2)(d)(iii) Applying Corrosion ProtectionFully coat the galvanized cable-type restrainer with corrosion-inhibiting grease and encapsulate it in asmooth HDPE sheath.

The sheath must be hot melt extruded onto the strand or must be shop applied by a method that ensuresall spaces between the sheath and the strand and between the strand wires are filled with corrosion-inhibiting grease.

The ends of the sheathing must be flush with the ends of the galvanized swaged fittings.

Cover the swaged fitting and a portion of the adjacent sheathed cable and threaded stud with a corrosionprotection system.

After final installation, the corrosion protection system must extend 2 inches onto both the sheathed cableand the threaded stud.

Clean the cable yield indicator, washers, disc spring, nut, and threaded stud under section 59-1.03C(4)and apply a prime coat of red calcium sulphonate penetrant.

Apply the prime coat to the specified dry film thickness in 1 or more applications. The total dry thicknessof the prime coat must be at least 1 mil.

Color code the disc springs after the application of the prime coat.

Coat the cable yield indicator, washers, disc spring, nut, and the portion of threaded stud from the outerface of the nut to and including the ends of the stud with a finish coat of gray calcium sulphate alkyd resin.

Apply the finish coat to the specified dry film thickness in 1 or more applications. The total dry thickness ofthe finish coat must be at least 8 mils.


REVISION 0


Apply the grease, sheathing, corrosion protection system, prime coat, and finish coat at themanufacturer's plant except do not apply the finish coat to any portion of the stud within 1-1/2 inches fromthe exposed end of the stud. After the cable restrainer installation is completed, recoat the parts specifiedin the 9th paragraph of section 75-1.03E(2)(d)(iii) that are accessible with the finish coat.

The items specified in section 75-1.03E(2)(a) to be submitted at the manufacturer's plant must besubmitted with all manufacturer's plant-applied coatings.

75-1.03E(3) Pipe TypePipe-type restrainers consist of double extra strong steel pipe and associated hardware.

Submit shop drawings showing the method of grouting pipe-type restrainers.

Double extra strong steel pipe must comply with ASTM A 53/A 53M, Grade B.

Bond pipe-type restrainers to existing concrete by completely filling the void between the pipe and thecored hole with grout within the limits shown. Grout must comply with section 50-1.02C. Provide fillermaterial and seals along the sides of the pipe to prevent grout from entering the bridge hinge joints. Thefiller material and seals must not restrict joint movement.

75-1.03E(4) Bar TypeBar-type restrainers consist of HS bars, bearing plates, couplers, anchorage devices, and incidentals.

Bar-type restrainers must comply with the material and sampling specifications for bar prestressing steelin section 50.

Clean and paint new metal surfaces of bar-type restrainer units after fabrication under the specificationsfor new structural steel in section 59-2, except SSPC-QP 1, SSPC-QP 2, and SSPC-QP 3 certificationsare not required.

Each anchorage device and coupler must develop the specified minimum ultimate tensile strength of thesteel bar and include locking devices to prevent turning or loosening.

You must determine the required length of each bar-type restrainer.

Bearing plates must comply with ASTM A 36/A 36M.

Elastomeric bearing pads must comply with section 51-3.02 and must be bonded to bearing plates withadhesive complying with Federal Specification MMM-A-121.

Ship each bar-type restrainer as a complete unit, including anchorage device and coupler.

75-1.03E(5)–75-1.03E(6) Not Used75-1.03F Nonskid SurfaceWhere a nonskid surface is shown on steel plates, apply an epoxy mixed with grit.

Submit a work plan for the nonskid surface showing:

1. Application method2. Spread rate of epoxy and grit3. Number of coats

Epoxy must comply with section 95-2.01, 95-2.03, or 95-2.09.

Grit must be:

1. Commercial-quality aluminum oxide, silicon carbide, or almandite garnet grit particles2. Screen size no. 12 to 30 or no. 14 to 353. Applied uniformly at a rate of at least 0.3 psf of surface area.

The finish color of the nonskid surface must be light gray.


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Before applying epoxy and grit to a galvanized surface, prepare the surface under section 59-3.03.

Before applying any nonskid material, prepare a 1 sq ft test sample applied on hardboard at least 1/4 inchthick. The nonskid surface must have a total thickness from 1/8 to 3/16 inch.

If authorized, you may use a commercial-quality nonskid surface made of a 2-component UV-resistantepoxy and grit if the quality is equal to the epoxy-grit mixture specified in section 75-1.03F.

75-1.03G Bearing DevicesBearing assemblies or masonry plates placed on mortar pads must comply with section 55-1.03C(2).

Set bearing plates level. Set rockers and expansion devices to comply with the temperature at the time oferection or to the specified setting.

75-1.03H–75-1.03J Not Used75-1.04 PUMPING PLANT METAL WORK75-1.05 GALVANIZINGGalvanizing must comply with the schedules and specifications shown in the following table except thatgalvanizing of miscellaneous bridge metal is not required for (1) portions of plates, shapes, or other itemsembedded more than 2 inches in concrete; (2) embedded steel pipe ending at or below the surface ofencasing concrete; and (3) items described to receive other finishes.


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Galvanizing Schedules and SpecificationsMaterial Schedulea Specification

Rolled, pressed, andforged steel shapes,plates, bars, and strip1/8 inch thick

Except for pregalvanizedstandard pipe, galvanizematerial after fabrication intothe largest practical sections.

ASTM A 123/A123M

Steel <1/8 inch thick Galvanize before or afterfabrication

If galvanized before fabrication, ASTMA 653/A 653M, Coating DesignationG210.If galvanized after fabrication, ASTM A123/A123M except the weight of zinccoating must average at least 1.2 oz/sqft of surface area with no individualspecimen having a coating weight ofless than 1.0 oz/sq ft.

Standard pipe -- ASTM A 53/A 53M except the zinccoating for fence pipes and structuralshapes except for metal line posts forbarbed and woven wire fences mustaverage at least 1.2 oz/sq ft of surfacearea with no individual specimenhaving a coating weight of less than1.0 oz/sq ft.

Iron and steel hardwareexcept threaded studs,bolts, nuts, and washersspecified to comply withASTM A 307, A 325, A449, A 563, F 436, or F1554b

Galvanize after fabrication. ASTM A 153/A 153M

Rail elements, backupplates, terminal sections,and end and return caps ofmetal beam guard railing

-- AASHTO M 180

aFabrication includes shearing, cutting, punching, forming, drilling, milling, bending, welding, andriveting.bFor threaded studs, bolts, nuts, and washers specified to comply with ASTM A 307, A 325, A 449, A563, F 436, or F 1554, galvanize under their ASTMs.

Galvanizing is not required for stainless steel, monel metal, and similar corrosion-resistant parts.

Clean welded areas before galvanizing to remove slag or other material that would interfere with theadherence of the zinc.

Galvanize parts of fastener assemblies separately before assembly.

Tapping of nuts or other internally threaded parts to be used with zinc-coated bolts, anchor bars, or studsmust be performed after galvanizing and must comply with thread dimensions and overtappingallowances in ASTM A 563.

Repair damaged galvanized surfaces as follows:

1. Clean by thoroughly wire brushing damaged areas and removing loose and cracked coating.2. Paint cleaned areas with 2 applications of organic zinc-rich primer from the Authorized Material List.

Do not use aerosol cans.


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76 WELLSNot Used

77 LOCAL INFRASTRUCTURENot Used

78–79 NOT USEDNot Used

80 FENCES80-1 GENERAL

80-1.01 GENERALSection 80-1 includes general specifications for constructing fences except Type ESA temporary fences.

80-1.02 CLEARINGRemove earth, trees, brush, and other obstructions that interfere with fence construction.

80-1.03 CONNECTIONSConnect new fences to existing fences.

Place a corner post with a brace for each direction of strain at each junction with an existing fence.

Fasten the wire in the new and existing fences to each post.

If ordered, at a structure, connect the new fence to the structure such that stock can pass freely throughor under the structure; otherwise, install an end post and connect the fence to it.

80-1.04 FOOTINGS AND DEADMENFor concrete for metal post and brace footings and for deadmen, use:

1. Commercial quality aggregates and cementitious material2. At least 470 pounds of cementitious material per cubic yard

Crown each concrete footing to shed water.

80-1.05 POST PLACEMENTMeasure post spacing parallel to the ground slope. Place each post in a vertical position except where theEngineer orders you to set the post perpendicular to the ground surface.

80-1.06 SURPLUS EXCAVATED MATERIALAfter constructing a fence, uniformly spread the surplus excavated material along the adjacent roadwaywhere designated by the Engineer.

80-1.07 TEMPORARY FENCESA temporary fence must comply with the Contract for a permanent fence of the same type except:

1. You may use used materials if the used materials are good, sound, and suitable for the purposeintended

2. Materials may be commercial quality if the dimensions and sizes of the materials are equal to orgreater than the dimensions and sizes shown on the plans or specified in section 80.

3. Posts must be either metal or wood4. The Department does not require:

4.1. Galvanizing or painting of steel elements4.2. Treating wood with a wood preservative4.3. Concrete footings for metal posts


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80-2 BARBED WIRE AND WIRE MESH FENCES80-2.01 GENERAL80-2.01A SummarySection 80-2 includes specifications for constructing barbed wire and wire mesh fences

80-2.01B Definitionsalignment angle: Change in a line where the angle of deflection is less than:

1. 5 degrees for a steel post barbed wire or wire mesh fence2. 15 degrees for a wood post barbed wire or wire mesh fence

corner: Change in a line where the angle of deflection exceeds:

1. 5 degrees for a steel post barbed wire or wire mesh fence2. 15 degrees for a wood post barbed wire or wire mesh fence

fence, Type BW: Barbed wire fence consisting of 5 lines of barbed wire.

fence, Type WM: Wire mesh fence consisting of wire mesh fabric and 3 lines of barbed wire.

80-2.01C SubmittalsNot Used

80-2.01D Quality Control and AssuranceNot Used


80-2.02B Metal Posts and BracesLine posts must comply with ASTM A 702 except packaging of posts is not required. Each post must beClass B steel. You may omit the anchor plate if the post is set in a concrete footing with a minimum crosssectional dimension of 6 inches and a depth equal to the full penetration of the post.

Each end, latch, pull, and corner post must have:

1. Minimum resisting section modulus of 0.32 cubic inch in any direction2. Length of at least 7 feet3. Weight of at least 3.1 lb/ft

Each brace and brace post must have:

1. Length of at least 7 feet2. Weight of at least 1.93 lb/ft

80-2.02C Wood Posts and Braces80-2.02C(1) GeneralEach wood post and brace must be treated except where untreated wood is specified.

Each wood line post to be driven must be machine pointed at the small end.

Sweep must not exceed 0.08 foot in 6 feet.

80-2.02C(2) UntreatedEach untreated wood post and brace must be:

1. Redwood, cedar, Douglas fir, or Southern yellow pine


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2. Straight and free from loose or unsound knots, shakes over 1/3 the post thickness, or other defectsthat would make it unfit structurally for the purpose intended

Post knots must be sound, tight, well spaced, and not over 2 inches on any face.

Each untreated wood line post and brace may be split material and must have:

1. Length of at least 7 feet2. Perimeter of at least 16 inches3. Each cross-section dimension of at least 4 inches

Each untreated wood end, corner, and brace post must be sawed or hewed and have:

1. Length of at least 8 feet2. Nominal size of at least 6 by 6 inches

80-2.02C(3) TreatedEach treated wood post and brace must be:

1. Douglas fir, Hem-Fir, Southern yellow pine2. Round or sawed rectangular3. Free of heart center

Each Douglas fir, Hem-Fir, and Southern yellow pine post and brace must be graded under section 57 ofthe Standard Specifications.

Each sawed post and brace must be of the minimum grade and species shown in the following table:

Grades and SpeciesNominal size Minimum grade Species4 by 4 inch Construction light framing Douglas fir

No. 1 structural light framing Hem-FirNo. 2 structural light framing Southern yellow pine

6 by 6 inch Select structural posts and timbers No. 1 Douglas firSelect structural posts and timbers Hem-FirNo. 1 timbers Southern yellow pine

Each round post and brace must be free from:

1. Decay2. Shakes over 1/3 the post diameter3. Splits longer than the thickness or diameter of the post4. Loose or unsound knots5. Multiple crooks6. Other defects that would weaken the post or brace or otherwise make it structurally unsuitable for the

purpose intended

Pressure treat each post and brace under section 57 of the Standard Specifications and AWPA U1, UseCategory UC4A, Commodity Specification A or B.

Treat posts after pointing.

Instead of the imprint specified in section 57 of the Standard Specifications, the treating plant mayhammer stamp either end of a treated post and brace with the symbol or name of the companyperforming the treatment.

For each round post and brace:


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1. Peel to remove outer bark and inner cambium bark except minimal strips of inner bark may remain ifnot over 1/2 inch wide or over 3 inches long

2. Trim knots flush with sides3. Remove spurs and splinters4. Cut ends square

Each line post and brace must be 7 feet long. Any other post must be 8 feet long. Each length may be atmost 1 inch shorter and 2 inches longer.

The small end of each round line post and brace must have a cross-sectional dimension between 3-1/2and 5 inches. The small end of any other round post must have a cross-sectional dimension between 5-1/2 and 7 inches.

The taper from end to end of each round post and brace must not exceed 1-1/2 inches.

Each sawed rectangular line post must have a nominal size of at least 4 by 4 inches. Any other sawedrectangular post must have a nominal size of at least 6 by 6 inches.

80-2.02D Barbed WireBarbed wire must:

1. Comply with ASTM A 1212. Have 2 point barbs3. Be one of the following:

3.1. 12-1/2 gage, Class 13.2. 13-1/2 gage, Class 33.3. 15-1/2 gage, Class 3

80-2.02E Wire MeshWire mesh must:

1. Comply with ASTM A 116, Class 12. Be 32 inches wide3. Have 8 horizontal wires with vertical stays spaced 6 inches apart

The top and bottom wires must be 10 gage.

The intermediate wires and vertical stays must be 12-1/2 gage.

80-2.02F Tension Wires, Hardware, and Grounding MaterialsTension wire must be 8-gage galvanized wire.

Galvanized bolts and nuts for attaching braces and straps to metal posts and galvanized devices forholding barbed wire and wire mesh in position must be commercial quality.

Each staple used to fasten barbed wire and wire mesh fabric to wood posts must be:

1. At least 1-3/4 inches long2. Manufactured from 9-gage galvanized wire

Wire used to fasten barbed wire and wire mesh to metal posts must be galvanized and at least 11 gage.Clips and hog rings used for metal posts must be at least 9 gage.

Wire used to tie the lower line of barbed wire to the top wire of wire mesh must be 12-gage galvanizedwire.

Each ground rod must:

1. Be galvanized or copper-coated steel2. Be 8 feet long


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3. Have a diameter of at least 1/2 inch

Conductor must be no. 6 solid copper or equal.

80-2.02G GatewaysFence materials and end post bracing must comply with the specifications and plans for the fence type inwhich the gateway is constructed.

Except for length, end bars must comply with the line post specifications and plans.

Vertical stays for gateways must be:

1. Pretwisted2. 9.5-gage galvanized wire3. Evenly spaced between end bars at 66-inch maximum intervals

Wire loops must be 6-gage galvanized wire.

The chain for the latching device must be commercial quality short link steel coil chain. The latching barfor the latching device must be commercial quality steel pipe. Bolts and nuts for attaching the chain to theend posts and latching bar must be commercial quality and galvanized.

81 MONUMENTSNot Used

DIVISION IX TRAFFIC CONTROL FACILITIES82 MARKERS AND DELINEATORS

Not Used

83 RAILINGS AND BARRIERS83-1 RAILINGS

83-1.01 GENERALSection 83-1 includes specifications for constructing railing.

83-1.02 MATERIALS AND CONSTRUCTION83-1.02A GeneralMaterials and construction for the various types of railings must comply with section 83-1.02.

At locations where traffic is adjacent to metal beam guard railing work, all materials required to completethe guard railing work at any 1 location must be available before work starts at that location.

At locations exposed to traffic, schedule activities so that at the end of each day no post holes are openand no railing posts are installed without the blocks and rail elements assembled and mounted.

Welding must comply with AWS D1.1. Welds on exposed surfaces must be ground flush with the adjacentsurfaces.

Galvanize completed steel parts and hardware for railings under section 75-1.05.

After galvanizing, railing elements must (1) be free of fins, abrasions, rough or sharp edges, and othersurface defects and (2) not be kinked, twisted, or bent. If straightening is necessary, the method usedmust be authorized. Railing elements with kinks, twists, or bends may be rejected.

Clean and regalvanize (1) abraded or damaged galvanized surfaces of steel railing and posts and (2)ends of steel railing cut after galvanizing, except if allowed by the Engineer, you may make repairs to thesurfaces under section 75-1.05.


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Mortar must comply with the specifications for mortar in section 51-1 and consist of 1 part by volume ofcement and 3 parts by volume of clean sand.

Cure mortar by either the water method or the curing compound method using curing compound no. 6.

Excavation and backfill must comply with section 19.

Steel bridge railing, concrete railing, and tubular metal railing must present a smooth, uniform appearancein its final position, conforming closely to the horizontal and vertical lines shown or ordered.

After constructing the railing, dispose of surplus excavated material uniformly along the adjacentroadway, except as specified in section 14-11 of the Standard Specifications.

83-1.02B Metal Beam Guard RailingNot Used

83-1.02D Steel Bridge Railing83-1.02D(1) GeneralSteel bridge railing consists of steel railing fabricated from structural shapes, pipe, formed sections,tubing, plates, and bars.

Structural shapes, tubing, plates, bars, bolts, nuts, and washers must comply with section 55-1.02. Otherfittings must be commercial quality.

Pipe sections must be standard steel pipe.

Formed sections must be:

1. Formed from mild steel and true to dimensions2. Free from kinks, twists, and bends3. Uniform in appearance

Closed sections must be made of 1-piece tubing or of 2 bent plates welded together at the longitudinaljoints.

Seams in the posts must be in the faces of the posts normal to the plane of the railing.

Mechanical expansion anchors for attaching the railing to the supporting concrete members must complywith the specifications for concrete anchorage devices in section 75-1.03A.

Railings must conform to the curvature by means of a series of short chords, from center to center of railposts, except that railing described as conforming to the curvature must be shop bent to fit the curvature.Joints must be matchmarked.

Railings must be carefully erected true to line and grade. Posts and balusters must be vertical within atolerance not to exceed 0.02 foot in 10 feet. Adjacent railing panels must align with each other within 1/16inch.

Posts must be mortared in sockets, set on mortar pads, or set on steel or concrete supporting membersas shown.

83-1.02D(2) California Bridge RailingNot Used

83-1.02E Cable RailingCable railing must consist of cables supported by pipe posts set in either concrete footings or postpockets in the tops of retaining walls or other structures.

Pipe for posts and braces must be standard steel pipe or pipe that complies with section 80-2.02.


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Truss rods, post tops, cable clamps, eye bolts, thimbles, and other required fittings must be commercialquality steel, malleable iron, or wrought iron. Post tops must be watertight. The eye of the eye bolts mustbe either drop forged or formed with a complete penetration weld. The eye must develop 100 percent ofthe bolt strength.

Turnbuckles must:

1. Be commercial quality2. Have jaw or eye ends3. Have a minimum breaking strength of 2,700 lb4. Be steel pipe type or drop-forged steel

Crimped sleeve clamps and stop sleeve clamps must:

1. Be nonferrous metal2. Develop the strength of the cable3. Be the color of the cable

Cable must:

1. Be wire strand or rope2. Have a minimum diameter of 1/4 inch3. Have a minimum breaking strength of 1,800 lb

Galvanize cable under Federal Specification RR-W-410.

Tension cable to provide taut railings between posts.

Construct post footings of minor concrete.

83-1.02F Concrete RailingConcrete railing consists of either an all-reinforced concrete section or the reinforced concrete portion ofcomposite railing sections with end and intermediate posts.

Concrete railing must comply with sections 51 and 52.

If ordered, adjust the height of the concrete railing to allow for the camber and dead load deflection of thesuperstructure. The amount of adjustment will be ordered before the concrete is placed.

83-1.02G Metal Railing83-1.02G(1) GeneralMetal railing consists of metal elements mounted on concrete members.

83-1.02G(2) Tubular Metal RailingTubular metal railing and tubular hand railing consists of tubular metal rails supported by metal posts,anchor bolts, hardware, and fittings.

Materials for tubular rails, posts, rods, bolts, and nuts must comply with the requirements shown in thefollowing table:

Material ASTMTubular steel rails and tubular handrailing A 500, Grade BSteel posts, rolled bars, and plate washers A 36/A 36MSteel sleeves for tubular rails A 36/A 36MHS bolts A 325, A 325M, or A 449HS threaded rods A 449Nuts and washers for HS bolts and rods A 325 or A 325M


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Stud bolts must comply with the specifications for stud connectors in section 55-1.02.

HS bolts or threaded rods furnished under ASTM A 449 must comply with the mechanical requirementsspecified in ASTM A 449 after galvanizing.

The metal railing posts to which the chain link railing attaches must fit the mounting brackets, pipesleeves, and other connection fittings.

Install shims at posts and railings, where necessary, to provide uniform bearing and conformance with thehorizontal lines and vertical grade lines. Shims at steel posts must be commercial quality, galvanizedsheet steel.

For tubular hand railing mounted on Type 80 SW concrete barrier railing:

1. Resin capsule anchors and threaded rods must comply with section 75-1.03A.2. Drilling and bonding threaded rods must comply with the specifications for drilling and bonding dowels

in section 51-1.

If the horizontal radius of the railing is 30 feet or less, that portion of the tubular railing must be eithershop bent or built up from 1/4-inch-thick structural steel plates. Structural steel plates must comply withASTM A 36/A 36M. Built up tubular railing must match the seamless tubing in appearance.

The difference between out-to-out rail sleeve dimensions and the clear inside dimensions of the tubularsteel rails must not exceed 3/16 inch after galvanizing.

Submit 2 sets of anchor bolt layouts before placing parapet or other structural support reinforcement.

Carefully handle materials to avoid bending, braking, abrading, or otherwise damaging the parts. Do notuse manufacturing, handling, or installation methods that damage or distort the members or damage thegalvanizing.

Before the railing parts are assembled, clean bearing surfaces and surfaces to be in permanent contact.The bases of posts must be true and flat to provide uniform bearing on the concrete portions of the railing.

Adjust the vertical position of the metal railing to allow for camber and dead load deflection of thesuperstructure. The amount of adjustment will be ordered before the metal railing is installed.

83-1.02G(3) Pipe HandrailingPipe handrailing consists of handrailing elements supported by metal brackets or tubular steel posts.

Handrailing elements must be either structural tubing for tubular steel posts or commercial qualitystandard steel pipe. Tubular steel posts must be round, seamless or welded structural tubing complyingwith ASTM A 501 and have a wall thickness not less than that of standard steel pipe of the same nominalsize.

Brackets, bolts, threaded studs, nuts, washers, and other fittings must be commercial quality structuralsteel, except that standard steel pipe fittings may be used where shown.

Mechanical expansion anchors for attaching the railing to supporting concrete members must comply withthe specifications for concrete anchorage devices in section 75-1.03A.

Railing must be carefully erected true to line and grade. Posts must be vertical within a tolerance not toexceed 0.02 foot in 10 feet and set in sockets or on mortar pads.

83-1.02G(4) Ornamental RailingNot Used


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83-1.02H Not Used83-1.02I Chain Link RailingChain link railing consists of a metal frame covered with chain link fabric, including posts, horizontalmembers, post anchorages, stretcher bars, truss rods, tension wires, and other required hardware andfittings.

Posts and horizontal members must be standard steel pipe, structural steel tubing, or structural shapes,except where metal conduit is specified. Structural tubing steel must comply with ASTM A 500 or A 501.

Structural shapes, plates, bars, and bolts must comply with section 55-1.02.

Stretcher bars, truss rods, post tops, and other required fittings and hardware must be steel, malleableiron, or wrought iron. Post tops and other closures must be watertight. Fittings and hardware must fastenproperly to the posts and other members.

Cable used in the frame must:

1. Be wire rope2. Be 5/16 inch in diameter3. Have a minimum breaking strength of 5,000 lb4. Be galvanized under Federal Specification RR-W-410

Crimped sleeve clamps and stud socket assemblies must:

1. Be metal2. Develop the strength of the cable3. Be the color of the cable

Frame members carrying electrical conductors must be rigid metal conduit manufactured of mild steelcomplying with UL 6, Electrical Rigid Metal Conduit - Steel. Zinc coat the interior and exterior surfaces ofthe rigid metallic conduit by hot-dip galvanizing.

Tension wires must be at least 7-gage coil spring steel.

Post clips must be at least 9-gage steel.

Wire ties or hog rings must be 9-gage, commercial quality, steel wire. Wire ties must be given at least 1complete turn.

Galvanize tension wires, post clips, wire ties, and hog rings under ASTM A 116, Coating Type Z, Class 3.

Six-gage (0.192-inch minimum diameter) aluminum wire ties complying with ASTM B 211 or B 211M,Alloy 1100-H18, or 6-gage (0.192-inch minimum diameter) aluminum hog rings complying with ASTM B211 or B 211M, Alloy 6061-T94 or Alloy 5052-H38 may be substituted for steel wire ties or hog rings.

Bend ends of wire ties away from pedestrian traffic.

Chain link fabric must be 11 gage and must comply with one of the following:

1. AASHTO M 181, Type I, Class C2. AASHTO M 181, Type IV, Class A3. ASTM F 1345, Class 2

The color of vinyl-coated chain link fabric must be either medium green or dark green.

The railings pertaining to a structure must all be the same color.

Chain link fabric must be woven into approximately 1-inch mesh.

Tighten truss rods and cables with turnbuckles or other fittings.


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Stretch and fasten the fabric securely to the posts, other members, and tension wires. Stretch tensionwires tightly.

Wherever necessary to conform to curvature, either horizontal or vertical, rework and fit the fabric topresent a smooth, neat, and workmanlike appearance.

Provide openings in the fabric as required by other facilities. Reinforce openings with not less than 1 turnof 6-gage wire.

Attach pipe handrailing to chain link railing where shown. Handrailing must comply with section 83-1.02G(3).

83-1.02J Pedestrian BarricadeInstall pedestrian barricade as shown.

83-2 BARRIERS83-2.01 GENERALSection 83-2 includes specifications for constructing barrier.

Trim existing median planting to clear the work area for median barrier construction. Dispose oftrimmings.

Do not remove an existing median barrier more than 500 feet in advance of the construction of the newbarrier being constructed.

At locations exposed to traffic, schedule activities so that at the end of each day no post holes are openand no barrier posts are installed without the blocks and rail elements assembled and mounted.

At the end of each day's activities, reset the existing median barrier without mesh or glare screen andanchor as authorized so that no gap is left between the reset barrier and the barrier being installed. Youmay place Type K temporary railing instead of resetting the existing barrier.

83-2.02 MATERIALS AND CONSTRUCTION83-2.02A GeneralNot Used

83-2.02B Thrie Beam BarrierNot Used

83-2.02B(1) Minor Concrete Vegetation Control83-2.02B(2) Transition RailingNot Used

83-2.02C Not Used83-2.02D Concrete Barrier83-2.02D(1) GeneralConcrete barrier must comply with sections 51 and 52.

If a gap is left in the concrete barrier for equipment or special drainage features during construction onhighways open to traffic, close the gap by temporary or permanent means when work is not actively inprogress at the location of the gap.

The concrete barrier must present a smooth, uniform appearance in its final position, conforming closelyto the horizontal and vertical lines shown or ordered. The barrier must be free of lumps, sags, or otherirregularities.

The top and exposed faces of the barrier must comply with the following requirements when tested with a10-foot straightedge laid on the surfaces:


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1. For Type 50 and 60 series concrete barriers, the top must not vary more than 0.02 foot from the edgeof the straightedge and the faces must not vary more than 0.04 foot from the edge of thestraightedge.

2. For concrete barriers other than Type 50 and 60 series, both the top and faces must not vary morethan 0.02 foot from the edge of the straightedge.

If a concrete barrier is to be constructed on a recently completed bridge, adjust the height of the barrier toallow for the camber and dead load deflection of the superstructure. The amount of adjustment will beordered before the concrete is placed. Place the barrier after the falsework has been released and aslong after the superstructure construction as the progress of the work will allow, unless otherwise ordered.

If a concrete barrier is to be constructed on existing pavement or an existing structure, adjust the height ofthe barrier to allow for irregularities in the existing grade. The amount of adjustment will be ordered beforethe concrete is placed.

If a concrete barrier is to be constructed on an existing structure, bond the dowels in drilled holes in theexisting concrete. Drilling of the holes and bonding of the dowels must comply with section 51.

If a concrete barrier is to be constructed to the face of an existing concrete structure, match the existingweep holes.

Locate expansion joints in the barrier at deck, pavement, and principal wall joints. Expansion joint fillermaterial must be the same size as the joint or 1/2 inch minimum.

Cement concrete barrier markers to the barrier under the manufacturer's instruction. Match the spacing ofthe markers to the spacing of the raised pavement markers on the adjacent median edgeline pavementdelineation.

Excavation and backfill must comply with section 19-3.

The portion of barrier below finished grade may be placed to the neat lines of the excavation.

For Type 50E, 60F, 60GE, and 60SF concrete barriers, granular material for backfill between the 2 wallsof concrete barrier must:

1. Be earthy material suitable for the purpose intended2. Have no rocks, lumps, or clods exceeding 1-1/2 inches in greatest dimension3. Be placed without compaction

At connections to structures, apply a uniform film of grease to the upper surface of the neoprene stripbefore placing the sheet metal.

The tubular lower railing for Type 80SW concrete barrier must comply with the specifications for tubularhandrailing in section 83-1.02G(2).

Forms for Type 80 series concrete barrier railing must remain in place for a minimum of 36 hours after theconcrete is placed.

If the project is in a freeze-thaw area, the barrier must comply with the following requirements:

1. Concrete must contain not less than 675 pounds of cementitious material per cubic yard.2. Bar reinforcing steel must comply with section 52-2.02.3. Concrete barriers on bridges or walls must be cured by the water method.For a concrete barrier transition:

1. Remove portions of the existing concrete barrier where shown under section 15-32. Roughen the contact surface of the existing concrete barrier3. Drill and bond dowels into the existing concrete barrier under section 51-1

83-2.02D(2) MaterialsConstruct Type 50 and 60 series concrete barriers of minor concrete, except as follows:


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1. Maximum size of aggregate used for extruded or slip formed concrete barrier must be no larger than1-1/2 inches and no smaller than 3/8 inch.

2. If the 3/8-inch maximum size aggregate grading is used to construct extruded or slip formed concretebarrier, the concrete must contain not less than 675 pounds of cementitious material per cubic yard.

Concrete for concrete barriers other than Type 50 and 60 series must contain not less than 590 pounds ofcementitious material per cubic yard.

For Type 50E, 60F, 60GE, and 60SF concrete barriers, the concrete paving between the tops of the 2walls of the barrier and the optional concrete slab at the base between the 2 walls of the barrier must beconstructed of minor concrete.

Structural steel plates and hardware required to join the concrete barrier at gaps caused by foundationsof overhead signs, electroliers, drainage structures, and at other locations must comply with sections 75-1.03A and 75-1.05.

Polystyrene at connections to structures and transitions to bridge columns must comply with section 51-2.01B(1).

Sheet metal, neoprene strip, and grease required at connections to structures must comply with thefollowing:

1. Sheet metal must be commercial quality galvanized sheet steel, smooth and free of kinks, bends, orburrs. Joints in the sheet metal must be butt joints sealed with plastic duct sealing tape.

2. Neoprene strip must comply with section 51-2.04.3. Grease must comply with Society of Automotive Engineers AS 8660. A uniform film of grease must

be applied to the upper surface of the neoprene strip before placing the sheet metal.

83-2.02D(3) Construction MethodsType 50 and Type 60 series concrete barriers must be constructed by one of the following:

1. Cast-in-place-with-fixed-forms method2. Extrusion or slip form method3. Combination of both methods

Concrete barriers other than Type 50 and Type 60 series must be constructed by the cast-in-place-with-fixed-forms method.

83-2.02D(3)(a) Cast-In-Place with Fixed FormsConcrete barriers constructed by the cast-in-place-with-fixed-forms method must comply with section 51.

Precast mortar blocks must not be used to support the reinforcing steel on the traffic side of barriers.

83-2.02D(3)(b) Extrusion or Slip FormConcrete barriers constructed by using an extrusion or slip form machine or other similar type ofequipment must be of well-compacted, dense concrete, and the exposed surfaces must comply withsection 51. You may be required to furnish evidence of successful operation of the extrusion or slip formmachine or other equipment.

The combined aggregate grading for the minor concrete must be of grading to produce concrete of theshape and surface texture specified.

Concrete may be made with the materials continuously batched by volume and mixed in a continuousmixer under the batching and mixing requirements in ASTM C 685.

Concrete must be fed to the extrusion or slip form machine at a uniform rate. Operate the machine underenough uniform restraint to forward motion to produce a well-compacted mass of concrete free fromsurface pits larger than 1 inch in diameter and requiring no further finishing other than that under section83-2.02D(4).


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Concrete must be of a consistency such that after extrusion or slip forming it will maintain the shape ofthe barrier without support.

The grade for the top of the concrete barrier must be indicated by an offset guide line set from surveymarks established by the Engineer. The forming portion of the extrusion or slip form machine must bereadily adjustable vertically during the forward motion of the machine to conform to the predeterminedgrade line. A grade line gage or pointer must be attached to the machine such that a continualcomparison can be made between the barrier being placed and the established grade line as indicated bythe offset guide line.

Instead of the above method for maintaining the barrier grade, the extrusion or slip form machine may beoperated on rails or forms set at uniform depth below the predetermined finished top of the barrier gradeor on existing pavement or bridge decks.

You may construct expansion joints by sawing through the barrier section to its full depth. Insertion of jointfiller is not required.

If expansion joints are not constructed by sawing, construct the expansion joints under section 51.

If sawing or forming the joints is performed before the concrete has hardened, firmly support the adjacentportions of the barrier with close fitting shields.

If sawing or forming the joints is performed after the application of curing compound, treat the exposedfaces of the barrier in the vicinity of the joint with curing compound after sawing or forming the joints.

If extrusion or slip forming methods of placement are used, the horizontal reinforcing bars must be placedcontinuously.

83-2.02D(4) FinishingThe surface finish of Type 50 and Type 60 series concrete barriers, before the application of the curingcompound, must be free from surface pits larger than 1 inch in diameter and must be given a final softbrush finish with strokes parallel to the line of the barriers. Finishing with a brush application of grout isnot allowed.

To facilitate finishing, remove fixed forms for CIP Type 50 and Type 60 series concrete barriers as soonas possible after the concrete has set enough to maintain the shape of the barrier without support.

Not less than 7 days after placing Type 50 and Type 60 series concrete barriers, exposed surfaces mustreceive a light abrasive blast finish to achieve a uniform appearance.

The final surface finish of concrete barriers other than Type 50 and Type 60 series must be Class 1surface finish under section 51-1.03F(3). Alternative final surface finish methods must be submitted inwriting and must not be used unless authorized.

83-2.02D(5) CuringCure exposed surfaces of concrete barriers with curing compound no. 6. The formed surfaces of theconcrete barriers on bridges or walls that do not support soundwalls may be cured under section 90-1.03B(5) except keep the forms in place for a minimum of 12 hours after the concrete is placed. For Type50 and Type 60 series concrete barriers, apply curing compound by a mechanical sprayer capable ofapplying the curing compound to at least 1 entire side and the top of the concrete barrier in 1 applicationat a uniform rate of coverage. Protect the spray against wind.

84 TRAFFIC STRIPES AND PAVEMENT MARKINGSNot Used

85 PAVEMENT MARKERSNot Used


REVISION 0


86 ELECTRICAL SYSTEMSNot Used

DIVISION X MATERIALS87 MATERIALS–GENERAL

Not Used

88 GEOSYNTHETICS88-1.01 GENERAL88-1.01A SummarySection 88 includes specifications for furnishing geosynthetics.

88-1.01B SubmittalsFor each type of geosynthetic submit:

1. Certificate of compliance2. Test sample representing each lot3. MARV

Label submittals with the manufacturer's name and product information.

88-1.01C Quality Control and AssuranceTreat geosynthetics to resist degradation from exposure to sunlight. Furnish geosynthetics in covers toprotect against damage from moisture, sunlight, and shipping and storage.


88-1.02B Filter FabricGeosynthetics used for filter fabric must be permeable and nonwoven. Filter fabric must be manufacturedfrom one of the following:

1. Polyester2. Polypropylene3. Combined polyester and polypropylene

When tested under the referenced ASTMs, properties of filter fabric must have the values shown in thefollowing table:


REVISION 0


Filter Fabric

Property Test ValueClass A Class B Class C

Grab breaking load, 1-inch grip, lbmin in each direction

ASTMD 4632 157

Apparent elongation, percentmin in each direction

ASTMD 4632 50

Puncture strength, lbmin

ASTMD 6241 600

Ultraviolet resistance, percentmin retained grab breaking load, 500 hours

ASTMD 4355 70

Permittivity, sec-1 min ASTMD 4491 0.5 0.2 0.1

Apparent opening size, average roll value, U.S. standardsieve size, max

ASTMD 4751 40 60 70

Filter fabric must be Class A.

88-1.02C Geocomposite Wall DrainGeocomposite wall drain must consist of a polymeric core with filter fabric integrally bonded to one orboth sides of the core creating a stable drainage void.

Filter fabric must comply with section 88-1.02B.

Geocomposite wall drain must be no more than 2 inches thick.

When tested under ASTM D 4716, properties of geocomposite wall drain must have the value shown inthe following table:

Geocomposite Wall DrainProperty Test Value

Transmissivity, gal/min/ftgradient = 1.0, Normal stress = 5,000 psf ASTM D 4716 4

88-1.02D Geotechnical Subsurface Reinforcement88-1.02D(1) GeneralGeosynthetic reinforcement used for geotechnical subsurface reinforcement must be either geotextile orgeogrid.

When tested under ASTM D 4491, geotextile permittivity must be at least 0.05 sec-1.

Geogrid must have a regular and defined open area. The open area must be from 50 to 90 percent of thetotal grid area.

88-1.02D(2) Long Term Design StrengthDetermine the LTDS of geosynthetic reinforcement from the ultimate tensile strength in the primarystrength direction divided by reduction factors. Calculate LTDS from the guidelines in GeosyntheticResearch Institute Standard Practice GG4a, GRI GG4b, or GRI GT7.

The product of the reduction factors must be at least 1.30. Determine the reduction factor for creep usinga 75 year design life for permanent applications. For temporary applications, use a 5 year design life todetermine the reduction factor. Determine the installation damage reduction factor from thecharacteristics of backfill materials used.

If test data is not available, use default values of reduction factors in the Geosynthetic Research InstituteStandard Practice to determine LTDS.


REVISION 0


Submit the LTDS and its supporting calculations at least 15 days before placing geosyntheticreinforcement. The calculations must be signed by an engineer registered as a civil engineer in the State.Do not install unless authorized.

88-1.02E Silt Fence FabricWhen tested under the referenced ASTMs, the properties of silt fence fabric must have the values shownin the following table:

Silt Fence Fabric

Property Test ValueWoven Nonwoven

Grab breaking load, 1-inch grip, lbmin, in each direction ASTM D 4632 120 120

Apparent elongation, percentmin, in each direction ASTM D 4632 15 50

Water flow rate, gal per minute/sq ftmin and max average roll value ASTM D 4491 10–100 100–150

Permittivity, sec-1

min ASTM D 4491 0.05 1.1

Apparent opening size, inchesmax average roll value ASTM D 4751 0.023 0.012

Ultraviolet resistance, percentmin retained grab breaking load, 500 hours ASTM D 4355 70 70

88-1.02F Gravel-Filled BagWhen tested under the referenced ASTMs, the properties of gravel-filled bag must have the values shownin the following table:

Gravel-Filled Bag

Property Test Value

Grab breaking load, lb, 1-inch gripmin, in each direction ASTM D 4632 205

Water flow rate, gal per minute/sq ftmin and max average roll value ASTM D 4491 80–150

Permittivity, sec-1

min ASTM D 4491 0.2

Apparent opening size, inchesmax average roll value ASTM D 4751 0.016

Ultraviolet resistance, percentmin retained grab breaking load, 500 hours ASTM D 4355 70

88-1.02G Sediment Filter BagWhen tested under the referenced ASTMs, the properties of sediment filter bag must have the valuesshown in the following table:


REVISION 0


Sediment Filter Bag

Property Test ValuesWoven Nonwoven

Grab breaking load, lb, 1-inch gripmin, in each direction ASTM D 4632 200 250


Water flow rate, gal per minute/sq ftmin and max average roll value ASTM D 4491 100-200 75-200

Permittivity, sec-1

min ASTM D 4491 1.0 1.0


Ultraviolet resistance, %min retained grab breaking load,500 hr.

ASTM D 4355 70 70

88-1.02H Temporary CoverWhen tested under the referenced ASTMs, the properties of temporary cover must have the valuesshown in the following table:

Temporary Cover

Property TestValues

Woven NonwovenGrab breaking load, lb, 1-inch grip

min, in each direction ASTM D 4632 200 200


Water flow rate, gal per minute/sq ftmin and max average roll value ASTM D 4491 4-10 80-120

Permittivity, sec-1

min ASTM D 4491 0.05 1.0


Ultraviolet resistance, %min retained grab breaking load, 500 hr. ASTM D 4355 70 70

88-1.02I Rock Slope Protection FabricRSP fabric must be a permeable, nonwoven, needle-punched geotextile. The fabric must bemanufactured from one of the following:

1. Polyester2. Polypropylene3. Combined polyester and polypropylene

Polymers must be either virgin compounds or clean reworked material. Do not subject virgin compoundsto use or processing other than required for initial manufacture. Clean reworked material must bepreviously processed material from the processor's own production that has been reground, pelletized, orsolvated. The fabric must not contain more than 20 percent of clean reworked material by weight. Do notuse recycled materials from either post-consumer or post-industrial sources.

When tested under the referenced ASTMs, the properties of Class 8 and Class 10 RSP fabric must havethe values shown in the following table:


REVISION 0


RSP Fabric

Property Test ValueClass 8 Class 10

Mass, oz/sq ydmin ASTM D 5261 7.5 9.5

Grab breaking load, lb, 1-inch gripmin, in each direction ASTM D 4632 200 250


Permittivity, sec-1,min ASTM D 4491 1.0 0.70

Apparent opening size, U.S. Standard sieve size:min and max ASTM D 4751 70–100 70–100

Ultraviolet resistance, percentmin retained grab breaking load, 500 hours ASTM D 4355 70 70

88-1.02J Paving FabricGeosynthetics used for paving fabric must be nonwoven. When tested under the referenced ASTMs,properties of paving fabric must have the values shown in the following table:

Paving FabricProperty Test Value

Mass per unit area, oz/sq ydmin ASTM D 5261 4.1

Grab breaking load, lb, 1-inch gripmin, in each direction ASTM D 4632 100

Apparent elongation, percentmin, in each direction ASTM D 4632 50

Hydraulic bursting strength, psimin ASTM D 3786 200

Melting point, Fmin ASTM D 276 325

Asphalt retention, gal/sq ydmin ASTM D 6140 0.2

88-1.02K Paving MatGeosynthetics used for paving mat must be a nonwoven fiberglass and polyester hybrid material. Whentested under the referenced ASTMs, properties of paving mat must have the values shown in thefollowing table:

Paving MatProperty Test Value

Breaking force, lb/2 inchesmin ASTM D 5035 45

Ultimate elongation, percentmax ASTM D 5035 5

Mass per unit area, oz/sq ydmin ASTM D 5261 3.7

Melting point, Fmin ASTM D 276 400

Asphalt retention, gal/sq ydmin ASTM D 6140 0.10


REVISION 0


88-1.02L Paving GridGeosynthetics used for paving grid must be a geopolymer material formed into a grid of integrallyconnected elements with openings. When tested under the referenced ASTMs, properties of paving gridmust have the values shown in the following table:

Paving Grid

Property Test ValueClass I Class II Class III

Tensile strength at ultimate, lb/ina

minASTMD 6637 560 x 1,120 560 280

Aperture size, inchmin Calipered 0.5 0.5 0.5

Elongation, percentmax

ASTMD 6637 12 12 12

Mass per area, oz/sq ydmin

ASTMD 5261 16 10 5.5

Melting point, °Fmin

ASTMD 276 325 325 325

a For Class I, machine direction x cross direction. For Class II and Class III, both directions.

88-1.02M Paving Geocomposite GridPaving geocomposite grid must consist of a paving grid specified in section 88-1.02L bonded orintegrated with a paving fabric as specified in section 88-1.02J.

Paving geocomposite grid must have a peel strength of at least 10 lb/ft determined under ASTM D 413.

88-1.02N Geocomposite Strip MembraneGeocomposite strip membrane must be various widths of strips manufactured from asphaltic rubber andgeosynthetics. When tested under the referenced ASTMs, properties of geocomposite strip membranemust comply with the requirements shown in the following table:

Geocomposite Strip MembraneProperty Test Requirements

Strip tensile strength, lb/inchmin ASTM D 882 50

Elongation at break, percentmin ASTM D 882 50

Resistance to puncture, lbmin ASTM E 154 200

Permeance, permsmax

ASTM E 96 / E96M 0.10

Pliability, 1/4 inch mandrel with sample conditioned at25 °F ASTM D 146 No cracks in fabric or

bitumenMelting point, °F ASTM D 276 325

88-1.02O Subgrade Enhancement GeotextileSubgrade enhancement geotextilemust be either polyester or polypropylene. When tested under thereferenced ASTMs, properties of subgrade enhancement geotextile must have the values shown in thefollowing table:


REVISION 0


Subgrade Enhancement GeotextileProperty

TestValuea

ClassA1

ClassA2

ClassB1

ClassB2

ClassB3

Elongation at break, percent ASTM D4632 <50 50 <50 <50 50

Grab breaking load, lb, 1-inchgrip

min, in each direction

ASTM D4632 250 160 -- 320 200

Wide width tensile strength at 5percent strain, lb/ft

min

ASTM D4595 -- -- 2,000 -- --

Wide width tensile strength atultimate strength, lb/ft

min

ASTM D4595 -- -- 4,800 -- --

Tear strength, lbmin

ASTM D4533 90 60 -- 120 80

Puncture strength, lbmin

ASTM D6241 500 310 620 620 430

Permittivity, sec-1

minASTM D

4491 0.05 0.05 0.20 0.20 0.20

Apparent opening size, inchesmax

ASTM D4751 0.012 0.012 0.024 0.012 0.012

Ultraviolet resistance, percentmin retained grab breakingload, 500 hours

ASTM D4355 70 70 70 70 70

aValues are based on MARV in the weaker principal direction except apparent opening size isbased on maximum average roll value.

88-1.03 CONSTRUCTIONNot Used

89 NOT USED

90 CONCRETE90-1 GENERAL

90-1.01 GENERAL90-1.01A SummarySection 90-1 includes general specifications for furnishing, curing, and protecting concrete.

Concrete must be composed of cementitious material, fine aggregate, coarse aggregate, admixtures ifused, and water.

PCC must comply with the specifications for concrete.

90-1.01B Definitionsfree water: Total water in the concrete mixture minus the water absorbed by the aggregates in reaching a

saturated surface-dry condition.

reclaimed aggregate: Aggregate that has been recovered from plastic concrete by washing away thecementitious material.


REVISION 0


90-1.01C Submittals90-1.01C(1) GeneralNot Used

90-1.01C(2) Aggregate GradationBefore starting concrete work, submit the gradation of the primary aggregate nominal sizes. If theaggregate source changes, submit new gradations before using the aggregate.

If a primary coarse aggregate or the fine aggregate is separated into 2 or more sizes, submit thegradation and proposed proportions of each size combined mathematically to show 1 proposed gradation.Show the percentage passing for each applicable sieve size.

90-1.01C(3) Cementitious MaterialsSubmit a certificate of compliance for cementitious materials. Include the source name and location.

If the cementitious material is delivered directly to the job site, the certificate of compliance must besigned by the cementitious material supplier.

If the cementitious material is used in ready-mixed concrete, the certificate of compliance must be signedby the concrete manufacturer.

If blended cement is used, the certificate of compliance must include a statement signed by the blendedcement supplier that shows the actual percentage of SCM, by weight, in the blend. Determine the weightof SCM by weighing device as specified in section 9-1.02B of the Standard Specifications or by chemicalanalysis.

90-1.01C(4) AdmixturesIf you propose to use an admixture from the Authorized Material List, submit a certificate of compliancefrom the manufacturer certifying that the admixture furnished is the same as that previously authorized.

90-1.01C(5) Curing CompoundFor each batch of curing compound delivered to the job site, submit:

1. Certificate of compliance to the Engineer. The certificate of compliance must include:2.1. Test results for the tests specified in section 90-1.01D(6).2.2. Certification that the material was tested within 12 months before use.

If the curing compound is shipped in tanks or tank trucks, submit a shipping invoice with each load. Theinvoice must show the same information specified for container labels in section 90-1.03B(3)(b).

90-1.01C(6) Mix DesignSubmit the concrete mix design before using the concrete in the work and before changing the mixproportions or an aggregate source.

90-1.01C(7) Concrete DeliverySubmit a weighmaster certificate as an informational submittal with each load of concrete delivered to thejob site.

The weighmaster certificate must show:

1. Mix identification number.2. Nonrepeating load number.3. Date and time the materials were batched.4. Total quantity of water added to the load.5. For transit-mixed concrete, the revolution counter reading at the time the truck mixer is charged with

cement.6. Actual scale weights in pounds for the ingredients batched. Do not substitute theoretical or target

batch weights for actual scale weights.


REVISION 0


If authorized, you may submit the weighmaster certificates electronically instead of in printed form.

Submit weighmaster certificates in printed form or, if authorized, in electronic media. Present electronicmedia in a tab-delimited format on a CD or DVD. Captured data for the ingredients represented by eachbatch must be line feed carriage return and one line separate record with sufficient fields for the specifieddata.

90-1.01C(8) TestingIf the concrete is tested for shrinkage, submit the test data with the mix design.

If prequalification is specified, submit certified test data or trial batch test reports under section 90-1.01D(5)(b).

If 56 days are allowed for the concrete to attain the strength described, submit test results under section90-1.01D(5)(a).

90-1.01C(9) Stationary Mixer CertificationIf you weigh the SCM cumulatively with the cement for concrete completely mixed in a stationary mixer,submit certification of the stationary mixer under section 90-1.02F(4)(c).

90-1.01C(10) Protecting ConcreteIf requested, submit a plan for protecting the concrete.

90-1.01D Quality Control and Assurance90-1.01D(1) GeneralThe cementitious materials and the admixture type and brand must be on the Authorized Material List atthe time of the mix design submittal.

Both the coarse and fine aggregate must be on the Authorized Material List for the aggregate used inconcrete to be considered innocuous.

If requested, furnish test samples of the freshly mixed concrete and provide satisfactory facilities forobtaining the test samples.

90-1.01D(2) Cementitious Material ContentAdjust the batch proportions as necessary to produce concrete having the specified cementitious materialcontent.

The Engineer verifies compliance with the specified cementitious material content by testing underCalifornia Test 518 for cement content. For testing purposes, SCM is considered to be cement.

For all concrete except minor concrete, if the cementitious material, portland cement, or SCM content isless than the minimum required and is not within the batching tolerances allowed under section 90-1.02F(3), you must remove the concrete. However, if the Engineer determines that the concrete isstructurally adequate, the concrete may remain in place.

90-1.01D(3) ShrinkageIf shrinkage limitations are specified, test the concrete under AASHTO T 160, modified as follows:

1. Prepare specimens that have a 4- by 4-inch cross section.2. Remove each specimen from the mold 23 ± 1 hours after mixing the concrete and place the

specimen in lime water at 73 ± 3 degrees F until 7 days age.3. Take a comparator reading at 7 days age and record it as the initial reading.4. Store the specimens in a humidity-controlled room maintained at 73 ± 3 degrees F and 50 ± 4 percent

relative humidity for the remainder of the test.5. Take subsequent readings at 7, 14, 21, and 28 days drying.


REVISION 0


Perform AASHTO T 160 testing at a laboratory that is accredited to perform AASHTO T 160 or thatmaintains a current rating of 3 or better for the Cement and Concrete Reference Laboratory concreteproficiency sample program.

Shrinkage test data authorized by the Department no more than 3 years before the 1st day of theContract is authorized for the entire Contract. The test data must be for concrete with similar proportionsand using the same materials and material sources to be used on the Contract. Concrete is considered tohave similar proportions if no more than 2 mix design elements are varied and the variation is within thetolerances shown in the following table:

Mix design element Tolerance (±)Water to cementitious material ratio 0.03Total water content 5 percentCoarse aggregate content 10 percentFine aggregate content 10 percentSCM content 5 percentAdmixture as originally doseda 25 percentaAdmixtures must be the same brand.

90-1.01D(4) Concrete UniformityThe Engineer determines the uniformity of concrete mixtures based on differences in test results between2 test samples of mixed concrete from the same batch for the following tests:

1. California Test 533 if the mix design specifies a penetration value2. ASTM C 143 if the mix design specifies a slump value3. California Test 529

90-1.01D(5) Compressive Strength90-1.01D(5)(a) GeneralSection 90-1.01D(5) applies for either of the following cases:

1. Concrete is designated by compressive strength.2. Attaining a minimum concrete compressive strength is specified as a prerequisite to applying loads or

stresses to a concrete structure or member.

If the 28-day compressive strength described is 3,600 psi or greater, the concrete is designated bycompressive strength.

If the concrete is designated by compressive strength, the strength of concrete that is not steam cured isdetermined from cylinders cured under Method 1 of California Test 540.

If attaining a minimum concrete compressive strength is specified as a prerequisite to applying loads orstresses to a concrete structure or member, cylinders for concrete that is not steam cured are curedunder Method 1 of California Test 540 and the concrete compressive strength is evaluated based onindividual tests.

For concrete with a described 28-day compressive strength greater than 3,600 psi, 42 days are allowedto attain the strength described.

Except for concrete specified to be in a freeze-thaw area, 56 days are allowed to attain the strengthdescribed if the cementitious material satisfies the following equation:

[(41 x UF) + (19 x F) + (11 x SL)]/TC 7.0

where:


REVISION 0


F = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, including the quantity inblended cement, lb/cu yd. F is equivalent to the sum of FA and FB as defined in section 90-1.02B(3).

SL = GGBFS, including the quantity in blended cement, lb/cu ydUF = silica fume, metakaolin, or UFFA, including the quantity in blended cement, lb/cu ydTC = total quantity of cementitious material used, lb/cu yd

For concrete satisfying the equation above, test for the compressive strength at least once every 500 cuyd at 28, 42, and 56 days. Submit the test results to the Engineer.

The Engineer determines the concrete compressive strength from test cylinders:

1. Made from concrete sampled under California Test 5392. Molded and initially field cured under California Test 5403. Cured and tested under California Test 521

A compressive strength test represents no more than 300 cu yd of concrete and consists of the averagecompressive strength of 2 cylinders made from material taken from a single load of concrete. If a cylindershows evidence of improper sampling, molding, or testing, the cylinder is discarded and the test consistsof the compressive strength of the remaining cylinder.

If a single compressive strength test result is below the strength described at the maximum age specifiedor allowed, or if the compressive strength of concrete tested at 7 days indicates to the Engineer that theconcrete will not attain the strength described at the maximum age specified or allowed, correct the mixdesign or concrete fabrication procedures and obtain authorization before you place additional concrete.

If the compressive strength is below 85 percent of the strength described, you must remove the concrete.

If a strength test result at the maximum age specified or allowed is below 85 percent of the strengthdescribed, you must remove the concrete represented by the test unless you obtain and submit evidencethat the strength of the concrete placed in the work is at least 85 percent of the strength described andthis evidence is accepted by the Engineer.

If the evidence consists of tests made on cores taken from the work, obtain and test the cores underASTM C 42.

90-1.01D(5)(b) PrequalificationIf the concrete has a described 28-day compressive strength greater than 3,600 psi, or if prequalificationis specified, prequalify the materials, mix proportions, mixing equipment, and procedures proposed foruse in the work before placing the concrete.

Submit certified test data or trial batch test reports based on the same materials, mix proportions, mixingequipment, procedures, and batch size proposed for use in the work.

Certified test data must show that:

1. Results of 90 percent or more of at least 20 consecutive tests exceed the compressive strengthdescribed at the maximum number of days specified or allowed and none of the test results are lessthan 95 percent of the strength described

2. All tests are the most recent tests made on concrete of the proposed mix design and were madewithin 1 year of the proposed use of the concrete

Trial batch test reports must show that:

1. Average compressive strength for 5 consecutive concrete cylinders taken from a single batch andtested at not more than the maximum age specified or allowed is at least 600 psi greater than the 28-day compressive strength described

2. No individual cylinder has a strength less than the strength described at the maximum age specifiedor allowed


REVISION 0


3. Data contained in the report is from trial batches produced within 1 year of the proposed use of theconcrete

If air entrainment is specified, the air content of the trial batches must be greater than or equal to the aircontent specified for the concrete without reduction due to tolerances.

Perform tests under the appropriate California Test methods or comparable ASTM test methods. Usetesting equipment that is in good condition and properly calibrated. If tests are performed during theContract, notify the Engineer far enough in advance that the Engineer can witness the test procedures.

Certified test data and trial batch reports must include:

1. Date of mixing2. Mixing equipment and procedures3. Batch size in cubic yards4. Weight, type, and source for each ingredient5. Penetration or slump as specified in section 90-1.02G(6)6 Air content if an air-entraining admixture is used7. Concrete age at the time of testing8. Compressive strength for each cylinder tested9. Signature of an official of the testing firm

If authorized, you may use the concrete from trial batches in the work at locations where lower qualityconcrete is required.

Any change to the prequalified materials, mix proportions, mixing equipment, or procedures that couldresult in a concrete strength below that described requires additional prequalification by trial batch testing.

90-1.01D(6) Curing CompoundTest each batch of curing compound delivered to the job site for:

1. Water loss at 24 hours under California Test 5342. Reflectance under ASTM E 13473. Viscosity under ASTM D 21964. Nonvolatile content under ASTM D 23695. Pigment content under ASTM D 3723

A batch must be no larger than 10,000 gal.

The Engineer samples the curing compound at the manufacturer's supply source, at the job site, or atboth locations.

The curing compound sampled from shipping containers from the manufacturer's supply source or fromthe job site must match the test results for viscosity, nonvolatile content, and pigment content within thetolerances specified in the precision and bias statements for the test methods.

Additional testing of the curing compound may be required before its use if the compound has not beenused within 1 year or if the Engineer believes that the compound may no longer be acceptable.

90-1.02 MATERIALS90-1.02A GeneralConcrete for pavement, approach slabs, and bridge decks must comply with the shrinkage limitationsshown in the following table when tested under section 90-1.01D(3):


REVISION 0


Type of workMaximum length change of laboratory castspecimens at 28 days drying (average of 3)

(percent)Paving and approach slab concrete 0.050Bridge deck concrete 0.045

When tested for uniformity under section 90-1.01D(4), the differences in test results between the 2concrete test samples must comply with the following:

1. When tested under California Test 533, the difference in penetration values must not exceed 1/2 inch.2. When tested under ASTM C 143, the difference in slump values must not exceed the values shown in

the following table:

Average slump, S(inches)

Maximum permissible difference(inches)

S < 4 14 S 6 1-1/26 < S 9 2

3. When tested under California Test 529, the difference in the proportion of coarse aggregate must notexceed 170 pounds of aggregate per cubic yard of concrete.

Unless a modulus of rupture is specified, the minimum required compressive strength for concrete mustbe the greater of either the strength described or 2,500 psi. Proportion the concrete to attain the minimumrequired compressive strength.

For concrete not designated by compressive strength, the concrete must attain at least 85 percent of theminimum required compressive strength when tested at 28 days.

90-1.02B Cementitious Materials90-1.02B(1) GeneralUnless otherwise specified, the cementitious material must be one of the following:

1. Combination of Type II or V portland cement and SCM2. Blended cement

The cementitious materials used in CIP concrete for exposed surfaces of similar elements of a structuremust be from the same sources and of the same proportions.

Protect cementitious materials from moisture until used.

Place sacked cementitious materials in a pile to allow access for tallying, inspecting, and identifying eachshipment.

Provide facilities that ensure the cementitious materials to be used in the work are kept separate fromeach other and from other cementitious materials.

A storage silo containing a cementitious material must be emptied before using the silo for a differentcementitious material. Blended cements with a percentage of SCM differing by more than 2 percent areconsidered different cementitious materials.

Sample cementitious materials under California Test 125.

90-1.02B(2) CementPortland cemen must comply with ASTM C 150, except the C3S content of Type II cement must notexceed 65 percent.


REVISION 0


Blended cement must comply with portland blast-furnace slag cement, Type IS (MS), or portland-pozzolan cement, Type IP (MS), specified in AASHTO M 240, except:

1. Maximum limits on pozzolan content do not apply2. Blended cement must be composed of Type II or V cement and SCM produced by one of the

following methods:2.1. Intergrinding of portland cement clinker and granulated blast furnace slag, GGBFS, or

pozzolan2.2. Blending of portland cement and either GGBFS or finely divided pozzolan2.3. Combination of intergrinding and blending

Types II, III, and V portland cement must comply with the following:

1. Alkali content must not exceed 0.60 percent by mass of alkalies as Na2O + 0.658 K2O whendetermined under AASHTO T 105.

2. Autoclave expansion must not exceed 0.50 percent.

Type III portland cement may be used only if specified or authorized.

90-1.02B(3) Supplementary Cementitious MaterialsEach SCM must be one of the following:

1. Fly ash complying with AASHTO M 295, Class F, and either of the following:1.1. Available alkali as Na2O + 0.658 K2O must not exceed 1.5 percent when tested under ASTM C

311.1.2. Total alkali as Na2O + 0.658 K2O must not exceed 5.0 percent when tested under AASHTO T

105.2. UFFA complying with AASHTO M 295, Class F, and the chemical and physical requirements shown

in the following 2 tables:

Chemical property Requirement(percent)

Sulfur trioxide (SO3) 1.5 maxLoss on ignition 1.2 maxAvailable alkalies as Na2O + 0.658 K2O 1.5 max

Physical property Requirement(percent)

Particle size distributionLess than 3.5 microns 50Less than 9.0 microns 90

Strength activity index with portland cement7 days 95 (min percent of control)28 days 110 (min percent of control)

Expansion at 16 days when testing projectmaterials under ASTM C 1567a

0.10 max

aIn the test mix, at least 12 percent, by weight, of the Type II or V portlandcement must be replaced with UFFA.

3. Raw or calcined natural pozzolans complying with AASHTO M 295, Class N, and either of thefollowing:3.1. Available alkali as Na2O + 0.658 K2O must not exceed 1.5 percent when tested under ASTM C

311.3.2. Total alkali as Na2O + 0.658 K2O must not exceed 5.0 percent when tested under AASHTO T

105.


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4. Metakaolin complying with AASHTO M 295, Class N, and the chemical and physical requirementsshown in the following 2 tables:

Chemical property Requirement(percent)

Silicon dioxide (SiO2) + aluminum oxide (Al2O3) 92.0 minCalcium oxide (CaO) 1.0 maxSulfur trioxide (SO3) 1.0 maxLoss on ignition 1.2 maxAvailable alkalies as Na2O + 0.658 K2O 1.0 max

Physical property Requirement(percent)

Particle size distribution less than 45 microns 95Strength activity index with portland cement

7 days 100 (min percent of control)28 days 100 (min percent of control)

5. GGBFS complying with AASHTO M 302, Grade 100 or 120.6. Silica fume complying with AASHTO M 307, with a minimum reduction in mortar expansion of 80

percent when using the cement from the proposed mix design.

You may commingle fly ash from different sources at uncontrolled ratios if:

1. Each source produces fly ash complying with AASHTO M 295, Class F2. At the time of commingling, each fly ash has:

2.1. Running average of relative density that does not differ from any other fly ash by more than0.25

2.2. Running average of loss on ignition that does not differ from any other fly ash by more than 1percent

3. Final commingled fly ash complies with AASHTO M 295, Class F4. Fly ash supplier is responsible for testing the commingled fly ash

The quantity of portland cement and SCM in concrete must comply with the minimum cementitiousmaterial content specified.

The SCM content in concrete must comply with one of the following:

1. Any combination of portland cement and at least 1 SCM, satisfying equations 1 and 2:

Equation 1:

[(25 x UF) + (12 x FA) + (10 x FB) + (6 x SL)]/MC X

where:UF = silica fume, metakaolin, or UFFA, including the quantity in blended cement, lb/cu ydFA = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content of

up to 10 percent, including the quantity in blended cement, lb/cu ydFB = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content of

greater than 10 percent and up to 15 percent, including the quantity in blended cement, lb/cuyd

SL = GGBFS, including the quantity in blended cement, lb/cu ydMC = minimum quantity of cementitious material specified, lb/cu ydX = 1.8 for innocuous aggregate, 3.0 for all other aggregate


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Equation 2:

MC - MSCM - PC 0

where:MC = minimum quantity of cementitious material specified, lb/cu ydMSCM = minimum sum of SCMs that satisfies equation 1, lb/cu ydPC = quantity of portland cement, including the quantity in blended cement, lb/cu yd

2. 15 percent Class F fly ash with at least 48 oz of LiNO3 solution added per 100 lb of portland cement.The CaO content of the fly ash must not exceed 15 percent.

90-1.02C Aggregates90-1.02C(1) GeneralAggregates must be free from deleterious coatings, clay balls, roots, bark, sticks, rags, and otherextraneous material.

Provide safe and suitable facilities, including splitting devices, for obtaining aggregate test samples underCalifornia Test 125.

Aggregates must have:

1. Characteristics that enable the production of workable concrete within the limits of water contentspecified in section 90-1.02G(6).

2. No more than 10 percent loss when tested for soundness under California Test 214. The soundnessrequirement does not apply to fine aggregate if the durability index of the fine aggregate is 60 orgreater when tested under California Test 229.

The testing frequency for cleanness value, sand equivalent, and aggregate grading shall be inaccordance with the frequency for aggregate gradations in Section 03301-DB Portland Cement Concrete

If the results of any 1 or more of the cleanness value, sand equivalent, or aggregate grading tests do notcomply with the requirements for operating range, but all comply with the requirements for contractcompliance:

1. Suspend the concrete placement at the completion of the current pour2. Do not restart the concrete placement until test results or other information show that the next

material to be used in the work complies with the requirements for operating range

If the results of either or both of the cleanness value and coarse aggregate grading tests do not complywith the requirements for contract compliance, you must remove the concrete represented by the tests.

If the results of either or both of the sand equivalent and fine aggregate grading tests do not comply withthe requirements for contract compliance, you must remove the concrete represented by the tests.

The 2 preceding paragraphs apply individually to the contract compliance requirements for coarse andfine aggregate. If both coarse and fine aggregate do not comply with the contract compliancerequirements, both paragraphs apply.

90-1.02C(2) Coarse AggregateCoarse aggregate must consist of gravel, crushed gravel, crushed rock, reclaimed aggregate, crushedair-cooled iron blast furnace slag, or a combination of these.

Do not use crushed air-cooled iron blast furnace slag in reinforced or PS concrete.

Reclaimed aggregate must comply with the specifications for aggregate.

Coarse aggregate must comply with the requirements shown in the following table:


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Property California Test RequirementLoss in Los Angeles rattler after 500 revolutions 211 45 percent maxCleanness value

Operating range 227 75 minContract compliance 227 71 min

For cleanness value, an operating range limit of 71 minimum and a contract compliance limit of 68minimum apply if you submit a certificate of compliance certifying that:

1. Coarse aggregate sampled at the completion of processing at the aggregate production plant had acleanness value of at least 82 when tested under California Test 227

2. Prequalification tests performed under California Test 549 showed that the aggregate would developa relative strength of at least 95 percent and have a relative shrinkage of no more than 105 percentbased on concrete

90-1.02C(3) Fine AggregateFine aggregate must consist of natural sand, manufactured sand produced from larger aggregate, or acombination of these. Manufactured sand must be well graded.

Fine aggregate must comply with the requirements shown in the following table:

Property California Test RequirementOrganic impurities 213 Satisfactorya

Sand equivalent:Operating range 217 75 minContract compliance 217 71 min

aFine aggregate that develops a color darker than the referencestandard color may be authorized if 95 percent relative mortarstrength is achieved when tested under ASTM C 87.

For sand equivalent, an operating range limit of 71 minimum and a contract compliance limit of 68minimum apply if you submit a certificate of compliance certifying that:

1 Fine aggregate sampled at the completion of processing at the aggregate production plant had asand equivalent value of at least 82 when tested under California Test 217

2. Prequalification tests performed under California Test 549 showed that the aggregate would developa relative strength of at least 95 percent and have a relative shrinkage of no more than 105 percentbased on concrete

90-1.02C(4) Aggregate Gradings90-1.02C(4)(a) GeneralProposed aggregate gradations must be within the percentage passing limits shown in the following table:

Primary aggregatenominal size

Sievesize

Limits of proposedgradation

1-1/2 inch x 3/4 inch 1 in 19–411 inch x No. 4 3/4 in 52–851 inch x No. 4 3/8 in 15–381/2 inch x No. 4 3/8 in 40–783/8 inch x No. 8 3/8 in 50–85Fine aggregate No. 16 55–75Fine aggregate No. 30 34–46Fine aggregate No. 50 16–29


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The Engineer may waive, in writing, the specifications for gradation if in the Engineer's opinion furnishingthe gradation is not necessary for the work.

90-1.02C(4)(b) Coarse Aggregate GradingCoarse aggregate must be graded within the limits shown in the following table for each size of coarseaggregate:

Sievesize

Percentage passing primary aggregate nominal sizes1-1/2 inch x 3/4 inch 1 inch x No. 4 1/2 inch x No. 4 3/8 inch x No. 8

Operating Contract Operating Contract Operating Contract Operating Contractrange compliance range compliance range compliance range compliance

2 inch 100 100 -- -- -- -- -- --1-1/2inch 88–100 85–100 100 100 -- -- -- --

1 inch X ± 18 X ± 25 88–100 86–100 -- -- -- --3/4 inch 0–17 0–20 X ± 15 X ±22 100 100 -- --1/2 inch -- -- -- -- 82–100 80–100 100 1003/8 inch 0–7 0–9 X ± 15 X ± 22 X ± 15 X ± 22 X ± 15 X ± 20No. 4 -- -- 0–16 0–18 0–15 0–18 0–25 0–28No. 8 -- -- 0–6 0–7 0–6 0–7 0–6 0–7

NOTE: "X" is the gradation that you propose to furnish for the specific sieve size under section 90-1.02C(4)(a).

Furnish coarse aggregate for the 1-1/2-inch maximum combined aggregate grading under section 90-1.02C(4)(d) in 2 or more primary aggregate nominal sizes. You may separate each primary aggregatenominal size into 2 sizes and store them separately, provided that the combined material complies withthe grading specifications for the primary aggregate nominal size.

You may separate the coarse aggregate for the 1-inch maximum combined aggregate grading undersection 90-1.02C(4)(d) into 2 sizes and store them separately, provided that the combined materialcomplies with the grading specifications for the 1 inch x No. 4 primary aggregate nominal size.

90-1.02C(4)(c) Fine Aggregate GradingFine aggregate must be graded within the limits shown in the following table:

Sieve size Percentage passingOperating range Contract compliance

3/8 inch 100 100No. 4 95–100 93–100No. 8 65–95 61–99No. 16 X ± 10 X ± 13No. 30 X ± 9 X ± 12No. 50 X ± 6 X ± 9

No. 100 2–12 1–15No. 200 0–8 0–10

NOTE: "X" is the gradation that you propose to furnish for thespecific sieve size under section 90-1.02C(4)(a).

Fine aggregate sizes must be distributed such that the difference between the total percentage passingthe No. 16 and No. 30 sieves is from 10 to 40, and the difference between the percentage passing theNo. 30 and No. 50 sieves is from 10 to 40.

You may separate fine aggregate into 2 or more sizes and store them separately, provided that thecombined material complies with the grading specifications.


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90-1.02C(4)(d) Combined Aggregate GradingUse combined aggregate grading limits only for the design of concrete mixes. Design concrete mixessuch that aggregates are combined in proportions that produce a mixture within the grading limits forcombined aggregate.

Use either the 1-1/2-inch maximum grading or the 1-inch maximum grading, unless otherwise specified.

Combined aggregate must be graded within the limits shown in the following table:

Sieve size Percentage passing1-1/2 inch max 1 inch max 1/2 inch max 3/8 inch max

2 inch 100 -- -- --1-1/2 inch 90–100 100 -- --1 inch 50–86 90–100 -- --3/4 inch 45–75 55–100 100 --1/2 inch -- -- 90–100 1003/8 inch 38–55 45–75 55–86 50–100No. 4 30–45 35–60 45–63 45–63No. 8 23–38 27–45 35–49 35–49No. 16 17–33 20–35 25–37 25–37No. 30 10–22 12–25 15–25 15–25No. 50 4–10 5–15 5–15 5–15No. 100 1–6 1–8 1–8 1–8No. 200 0–3 0–4 0–4 0–4

Do not change from one aggregate grading to another during the progress of the work.

90-1.02D WaterWater for washing aggregates, mixing concrete, and curing must not contain:

1. Oil2. Impurities at concentrations that cause either of the following results when compared to the same test

using distilled or deionized water:2.1. Change of more than 25 percent in the setting time of cement when tested under ASTM C 191

or ASTM C 2662.2. Reduction by more than 5 percent in the mortar compressive strength at 14 days when tested

under ASTM C 1093. Chlorides as Cl or sulfates as SO4 in excess of the values shown in the following table:

Type ofconcrete work

Maximumchloride as Cla

Maximumsulfate as SO4

b

Nonreinforced 2,000 ppm 1,500 ppmReinforced 1,000 ppm 1,300 ppmPS 650 ppm 1,300 ppmaWhen tested under California Test 422bWhen tested under California Test 417

Water for curing concrete must not contain impurities at concentrations that cause discoloration orsurface etching.

Water reclaimed from washing out the mixer may be used in mixing concrete. The water must not containcoloring agents or more than 300 ppm of alkalis as Na2O + 0.658 K2O as determined on the filtrate. Thespecific gravity of the water must not exceed 1.03 and must not vary more than ±0.010 during a day'sactivities.


REVISION 0


90-1.02E Admixtures90-1.02E(1) GeneralAdmixtures must comply with the following:

1. Chemical admixtures must comply with ASTM C 494.2. Air-entraining admixtures must comply with ASTM C 260.3. Lithium nitrate must be in an aqueous solution that complies with the following:

3.1. Lithium nitrate as LiNO3 must be 30 ± 0.5 percent by weight.3.2. Sulfate as SO4 must be less than 1,000 ppm.3.3. Chloride as Cl must be less than 1,000 ppm.3.4. Alkalis as Na2O + 0.658 K2O must be less than 1,000 ppm.

Chemical or air-entraining admixtures must not contain more than 1 percent chlorides as Cl by weight ofadmixture when tested under California Test 415.

Store and dispense the admixtures in liquid form.

Admixture properties must be uniform throughout their use in the work.

If more than 1 admixture is used, the admixtures must be compatible with each other such that thedesirable effects of all the admixtures used are realized.

Use chemical admixtures in compliance with the manufacturer's written instructions. The instructions mustinclude a statement that the admixture is compatible with the types and quantities of SCM used.

90-1.02E(2) Chemical AdmixturesIf the use of chemical admixtures is specified, use the dosage specified. If the dosage is not specified,use the dosage recommended by the admixture manufacturer.

You may use any of the following admixture types to conserve cementitious material or to facilitateconstruction:

1. Type A or F, water-reducing2. Type B, retarding3. Type D or G, water-reducing and retarding

If you use a water-reducing admixture or a water-reducing and retarding admixture, you may reduce thespecified cementitious material content by up to 5 percent by weight. The resulting concrete must containat least 505 pounds of cementitious material per cubic yard. If you reduce the cementitious materialcontent, use at least the admixture dosage used in authorizing the admixture as shown on the AuthorizedMaterial List.

You may use a Type S admixture.

You may use a Type C accelerating admixture. Inclusion of the Type C admixture in the mix design is notrequired if it is added to counteract changing conditions that contribute to delayed setting of the concreteand if the use or change in dosage of the admixture is authorized.

90-1.02E(3) Air-Entraining AdmixturesIf air entrainment is specified or ordered, use the quantity of air-entraining admixture that producesconcrete having the specified air content when tested under California Test 504.

If air entrainment is not specified or ordered, you may use an air-entraining admixture to facilitate the useof a construction procedure or equipment. The average air content of 3 successive tests must not exceed4 percent and each test value must be no more than 5.5 percent when tested under California Test 504.

90-1.02F Proportioning Concrete90-1.02F(1) GeneralNot Used


REVISION 0


90-1.02F(2) Storage of AggregatesStore or stockpile aggregates such that the coarse and fine particles of each size do not separate andvarious sizes do not intermix before proportioning.

Prevent contamination by foreign materials while storing, stockpiling, and handling aggregates.

If you store the aggregates at a batching or mixing plant that is erected after the Contract is awarded andis used for furnishing concrete for the work:

1. Prevent intermingling of different aggregate sizes by using measures such as the physical separationof stockpiles or the construction of bulkheads of adequate length and height

2. Prevent contamination of the aggregates by contact with the ground through measures such asplacing the aggregates on wooden platforms or on hardened surfaces made of concrete, asphaltconcrete, or cement-treated material

When placing the aggregates in storage or moving the aggregates from storage to the weigh hopper ofthe batching plant, do not use methods that cause:

1. Segregation, degradation, or the combining of materials of different gradings and result in anaggregate size failing to comply with the grading specifications at the weigh hopper

2. Excessive particle breakage

You may be required to use devices that reduce the impact of falling aggregates.

90-1.02F(3) Proportioning DevicesAutomatic weighing systems must comply with section 90-1.02F(4)(c). For an automatic device, the singleoperation of a switch or starter must be the only manual operation required to proportion the aggregates,cement, and SCM for 1 batch of concrete.

Insulate the weighing equipment against the vibration or movement of other plant equipment.

The weight of each batch of material must not vary from the weight designated by the Engineer by morethan the specified tolerances.

The weighing and measuring equipment must have the following zero tolerances:

1. For cumulative weighing of aggregates, ±0.5 percent of the designated total aggregate batch weight2. For weighing each aggregate size separately, ±0.5 percent of the designated batch weight for each

aggregate size3. For cumulative weighing of cement and SCM, ±0.5 percent of the designated total batch weight of the

cement and SCM4. For weighing cement and SCM separately, ±0.5 percent of their designated individual batch weights5. For measuring water, ±0.5 percent of its designated weight or volume

The weight indicated for a batch of material must not vary from the preselected scale setting by more thanthe following:

1. Aggregates weighed cumulatively must be within ±1.0 percent of the designated total aggregatebatch weight.

2. Aggregates weighed separately must be within ±1.5 percent of the designated batch weight of eachaggregate.

3. Cement weighed separately must be within +2 to -1 percent of the designated cement batch weight.4. SCM weighed separately must be within +2 to -1 percent of the designated SCM batch weight.5. For cement and SCM weighed cumulatively, the cement must be within +2 to -1 percent of the

designated cement batch weight and the total for cement and SCM must be within +2 to -1 percent ofthe sum of the designated cement and SCM batch weights.

6. Water must be within ±1.5 percent of the designated weight or volume of water.


REVISION 0


Each scale graduation must be no more than 0.001 of the total scale capacity. For each material beingweighed, use a scale with single graduations that indicate a weight not exceeding the maximumpermissible weight variation above, except that graduations less than 1 lb are not required.

90-1.02F(4) Proportioning90-1.02F(4)(a) GeneralProportioning consists of dividing the aggregates into the specified sizes, each stored in a separate bin,and combining the aggregates with cementitious material, admixtures if used, and water.

Proportion the aggregates by weight.

At the time of batching:

1. Aggregates must be dried and drained to a stable moisture content such that no visible separation ofwater from the aggregate occurs during transportation from the proportioning plant to the point ofmixing

2. Free moisture content of the fine aggregate must not exceed 8 percent of its saturated surface-dryweight

If the proportioning plant has separate supplies of the same size group of aggregate with differentmoisture content, specific gravity, or surface characteristics affecting workability, exhaust one supplybefore using another supply.

Weigh bulk Type IP (MS) or Type IS (MS) cement in an individual hopper and keep it separate from theaggregates until the ingredients are released for discharge into the mixer.

Bulk cement and SCM may be weighed in separate weigh hoppers or in the same weigh hopper. Keepthe cement and SCM separate from the aggregates until the ingredients are released for discharge intothe mixer.

If the cement and SCM are weighed in the same weigh hopper, weigh the cement first. If the cement andSCM are weighed in separate weigh hoppers, the weigh systems for the proportioning of the aggregate,the cement, and the SCM must be individual and distinct from all other weigh systems. To constitute anindividual and distinct material-weighing device, each weigh system must have a hopper, a lever system,and an indicator.

Discharge the cement and the SCM into the mixer simultaneously with the aggregate.

The scales and weigh hoppers for bulk weighing cement, SCM, or cement plus SCM must be separateand distinct from the aggregate weighing equipment.

For batches of 1 cu yd or more, the batching equipment must comply with one of the followingcombinations:

1. Separate boxes and separate scale and indicator for weighing each aggregate size2. Single box and scale indicator for all aggregates3. Single box or separate boxes and automatic weighing mechanism for all aggregates

If you are requested to check the accuracy of batch weights, determine the gross weight and tare weightof batch trucks, truck mixers, truck agitators, and nonagitating hauling equipment. Weigh the equipmentusing scales designated by the Engineer.

For proportioning pavement concrete, install and maintain in good operating condition an electronicallyactuated moisture meter that indicates, on a readily visible scale, changes in the moisture content of thefine aggregate as it is batched within a sensitivity of 0.5 percent by weight of the fine aggregate.

90-1.02F(4)(b) Proportioning and Dispensing Liquid AdmixturesLiquid admixture dispensers must:


REVISION 0


1. Have enough capacity to measure at 1 time the total quantity of admixture required for each batch ofconcrete

2. Include a graduated measuring unit that is accurate to within ±5 percent of the required quantity foreach batch of concrete

3. Be located and maintained such that the graduations can be read accurately from the point at whichproportioning is controlled to allow a visual check of batching accuracy before discharge

4. Have measuring units that are clearly marked for the type and quantity of admixture

Each liquid admixture dispensing system must be equipped with a sampling device that consists of avalve located in a safe and readily accessible position such that the Engineer can slowly withdraw a testsample.

If more than 1 liquid admixture is used in the concrete mix, each admixture must have a separatemeasuring unit and must be dispensed by injecting equipment located such that the admixtures are notmixed at high concentrations and do not interfere with the effectiveness of each other.

If an air-entraining admixture is used with other liquid admixtures, incorporate the air-entraining admixtureinto the mix first, unless you demonstrate that a different sequence improves performance.

If automatic proportioning devices are used, the liquid admixture dispensers must operate automaticallywith the batching control equipment. The dispensers must have an automatic warning system in goodoperating condition that provides a visible or audible signal at the point at which proportioning iscontrolled. The signal must activate if the quantity of admixture measured varies from the preselecteddosage by more than 5 percent or if the entire contents of the measuring unit are not emptied from thedispenser.

Add liquid admixtures to the premeasured batch water or discharge the admixtures into the stream ofwater such that they are well-dispersed throughout the batch.

You may dispense air-entraining admixtures directly into moist sand in the batching bins if you maintainadequate control of the concrete air content.

90-1.02F(4)(c) Automatic ProportioningAutomatic proportioning devices must be authorized by the Department.

The batching of the aggregate and the cement, SCM, or cement plus SCM must be interlocked such thata new batch cannot start until all weigh hoppers are empty, the proportioning devices are within zerotolerance, and the discharge gates are closed.

The interlock must not allow any part of the batch to be discharged until all aggregate hoppers and thecement and SCM hoppers or the cement plus SCM hopper are charged with weights that are within thetolerances specified in section 90-1.02F(3).

If interlocks are required for the cement and SCM charging mechanisms and the cement and SCM areweighed cumulatively, their charging mechanisms must be interlocked to prevent the introduction of SCMuntil the weight of cement in the cement weigh hopper is within the tolerances specified in section 90-1.02F(3).

If the concrete is mixed completely in a stationary mixer, weigh the SCM in a separate weigh hopper andintroduce the SCM and cement simultaneously into the mixer proportionately with the aggregate. If yousubmit certification that the stationary mixer is capable of mixing the cement, SCM, aggregates, and wateruniformly before discharge, you may weigh the SCM cumulatively with the cement. Certification mustinclude:

1. Test results for 2 compressive strength test cylinders taken within the first 1/3, and 2 compressivestrength test cylinders taken within the last 1/3, of a single batch of concrete discharged from thestationary mixer. Strength tests and cylinder preparation must comply with section 90-1.01D(5).

2. Calculations demonstrating that the average of the 2 compressive strengths taken within the first 1/3of the batch do not differ by more than 7.5 percent from the average of the 2 compressive strengthstaken within the last 1/3 of the batch.


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3. Mixer rotation speed and time of mixing before discharge that are required to produce a mix thatcomplies with the above requirements.

The discharge gate on the cement and SCM hoppers or the cement plus SCM hopper must be designedto allow the regulation of the flow of cement, SCM, or cement plus SCM into the aggregate.

If separate weigh boxes are used for each aggregate size, the discharge gates must allow the regulationof the flow of each aggregate size.

Material discharged from each bin must be controlled by gates or by mechanical conveyors.

The means of withdrawl from the bins and of discharge from the weigh box must be interlocked such thatnot more than 1 bin can discharge at a time and the weigh box cannot be tripped until the requiredquantity from each bin has been deposited into it.

If a separate weigh box is used for each aggregate size, all the weigh boxes may be operated anddischarged simultaneously.

If the discharge from the bins is controlled by gates, each gate must be actuated automatically such thatthe required weight is discharged into the weigh box, after which the gate must automatically close andlock.

The automatic weighing system must be designed to allow all required proportions to be set on theweighing controller at the same time.

90-1.02G Mixing and Transporting Concrete90-1.02G(1) GeneralMix the concrete in a mechanically operated mixer, except, if allowed by the Engineer, you may mixbatches not exceeding 1/3 cu yd by hand methods under section 90-1.02G(5).

Do not use equipment with components made of aluminum or magnesium alloys that could have contactwith plastic concrete during mixing, transporting, or pumping.

Concrete must be thoroughly mixed, homogeneous, and free of lumps or evidence of undispersedcementitious material.

90-1.02G(2) Machine MixingConcrete mixers must be the revolving drum or revolving blade type. Operate the mixing drum or bladesuniformly at the mixing speed recommended by the manufacturer. Do not use a mixer or agitator that hasan accumulation of hard concrete or mortar.

Immediately before placing the concrete, the temperature of the mixed concrete must be from 50 to 90degrees F. Cool or heat the aggregates and mixing water as necessary to produce concrete within thesetemperature limits. Do not heat the aggregates or water above 150 degrees F. Any ice used to cool theconcrete must be melted before the concrete is discharged from the mixer.

Charge the batch into the mixer such that some water enters before the cementitious materials andaggregates. Add all the water to the drum by the end of the first 1/4 of the specified mixing time. If theconcrete is delivered in a truck mixer, you may withhold a portion of the mixing water and, if allowed bythe Engineer, add it at the delivery point as specified in section 90-1.02G(3).

Batch and charge the cementitious materials into the mixer by means that will not cause:

1. Loss of cementitious materials due to the effect of wind2. Accumulation of cementitious materials on the surfaces of conveyors or hoppers3. Other conditions that reduce or vary the required quantity of cementitious material in the concrete

mixture


REVISION 0


Operate stationary mixers with an automatic timing device. The timing device and discharge mechanismmust be interlocked such that during normal operation no part of the batch is discharged before thespecified mixing time has elapsed.

The total time from the intermingling of damp aggregates and all cementitious materials to the start ofmixing must not exceed 30 minutes.

The batch size must not exceed the manufacturer's guaranteed capacity.

For pavement or base concrete, install and maintain suitable batch counters in good operating conditionat job site batching plants and stationary mixers. The batch counters must indicate the exact number ofbatches proportioned and mixed.

Mix and deliver the concrete to the job site by one of the following methods:

1. Central-mixed concrete, in which the concrete is mixed completely in a stationary mixer andtransported to the delivery point in a truck agitator or nonagitating hauling equipment.

2. Shrink-mixed concrete, in which the concrete is mixed partially in a stationary mixer and the mixing iscompleted in a truck mixer.

3. Transit-mixed concrete, in which the concrete is mixed completely in a truck mixer.

Agitators must be truck mixers operating at agitation speed or truck agitators. Each mixer and agitatormust have a metal plate attached in a prominent place that clearly shows:

1. Various uses for which the equipment is designed2. Manufacturer's guaranteed drum or container capacity in terms of the volume of mixed concrete3. Rotation speed of the mixing drum or blades

Truck mixers must have an electrically or mechanically actuated revolution counter that readily allowsverification of the number of revolutions of the drum or blades.

For shrink-mixed concrete, transfer concrete that has been partially mixed at a central plant into a truckmixer and comply with the specifications for transit-mixed concrete. Partial mixing in a central plant doesnot count toward the number of revolutions at mixing speed.

90-1.02G(3) Transporting Mixed ConcreteConform with ASTM C94 / C94M Standard Specification for Ready-Mixed Concrete

90-1.02G(4) Time or Quantity of MixingMixing of the concrete in a stationary mixer must continue for the required mixing time after allingredients, except water and admixture that is added with the water, are in the mixing compartment ofthe mixer before any part of the batch is released. The transfer time in multiple drum mixers must not becounted as part of the required mixing time.

For concrete used in concrete structures other than minor structures, the mixing time in a stationary mixermust be at least 90 seconds and no more than 5 minutes, except that if authorized the minimum mixingtime may be reduced to 50 seconds. For all other concrete, the mixing time must be at least 50 secondsand no more than 5 minutes.

The minimum required revolutions at the mixing speed for transit-mixed concrete must be at least thatrecommended by the mixer manufacturer and must be enough to produce uniform concrete under section90-1.02A.

90-1.02G(5) Hand MixingHand-mixed concrete must be made in batches of 1/3 cu yd or less.

Use the following procedure to make hand-mixed concrete:

1. Measure the quantity of coarse aggregate in measuring boxes.2. Spread the coarse aggregate on a watertight, level platform.


REVISION 0


3. Spread the fine aggregate on the layer of coarse aggregate. The total depth of the 2 layers must be 1foot or less.

4. Spread the dry cementitious materials on the aggregates.5. Turn the whole dry mass at least 2 times.6. Add and evenly distribute the water.7. Turn the whole mass at least 3 more times, not including placement in the carriers or forms.

90-1.02G(6) Quantity of Water and Penetration or SlumpRegulate the quantity of water used in the concrete mix such that the penetration as tested underCalifornia Test 533, or the slump as tested under ASTM C 143, complies with the nominal range shown inthe following table:

Type of workNominal Maximum

Penetration Slump Penetration Slump(inches) (inches) (inches) (inches)

Concrete pavement 0–1 -- 1.5 --Nonreinforced concrete facilities 0–1.5 -- 2 --Reinforced concrete structures with:

Sections over 12 inches thick 0–1.5 -- 2.5 --Sections 12 inches thick or less 0–2 -- 3 --

Concrete placed under water -- 6–8 -- 9CIP concrete piles 2.5–3.5 5–7 4 8

If the penetration or slump exceeds the nominal range, adjust the mixture for subsequent batches toreduce the penetration or slump to a value within the nominal range.

Do not use a batch of concrete with a penetration or a slump that exceeds the maximum value shown inthe table above.

If Type F or G chemical admixtures are used, the penetration requirements do not apply and the slumpmust not exceed 9 inches after adding the chemical admixtures.

The quantity of free water must not exceed 310 pounds per cubic yard of concrete plus 20 pounds of freewater for each required 100 pounds of cementitious material in excess of 550 pounds of cementitiousmaterial per cubic yard of concrete.

When determining the total quantity of free water, consider liquid admixtures to be water if the dosage ismore than 1/2 gallon of admixture per cubic yard of concrete.

If there are adverse or difficult conditions that affect concrete placement, you may exceed the specifiedpenetration and free water content limitations if you:

1. Receive authorization to increase the cementitious material content per cubic yard of concrete2. Increase the water and cementitious material at a ratio that does not exceed 30 pounds of water per

added 100 pounds of cementitious material per cubic yard of concrete

The equipment for supplying water to the mixer must accurately measure to within 1.5 percent of thequantity of water required to be added to the mix for any position of the mixer.

The tanks used to measure the water must be designed such that water cannot enter while water is beingdischarged into the mixer. The water must be discharged into the mixer rapidly in 1 operation withoutdribbling.

Arrange the equipment to allow checking of the quantity of water delivered by discharging into measuredcontainers.

90-1.02H Concrete in Corrosive EnvironmentsSection 90-1.02H applies to concrete specified in these specifications to be in a corrosive environment.


REVISION 0


The cementitious material to be used in the concrete must be a combination of Type II or V portlandcement and SCM.

The concrete must contain at least 675 pounds of cementitious material per cubic yard.

The reduction of cementitious material content as specified in section 90-1.02E(2) is not allowed.

The specifications for SCM content in section 90-1.02B(3) do not apply.

The cementitious material must be composed of one of the following, by weight:

1. 25 percent natural pozzolan or fly ash with a CaO content of up to 10 percent and 75 percent portlandcement

2. 20 percent natural pozzolan or fly ash with a CaO content of up to 10 percent, 5 percent silica fume,and 75 percent portland cement

3. 12 percent silica fume, metakaolin, or UFFA, and 88 percent portland cement4. 50 percent GGBFS and 50 percent portland cement

90-1.02I Concrete in Freeze-Thaw Areas90-1.02I(1) GeneralSection 90-1.02I applies to concrete for projects specified in these specifications to be in a freeze-thawarea.

90-1.02I(2) Materials90-1.02I(2)(a) GeneralThe concrete must contain at least 590 pounds of cementitious material per cubic yard unless a highercementitious material content is specified.

Add an air-entraining admixture to the concrete at the rate required to produce an air content of 6.0 ± 1.5percent in the freshly mixed concrete.

For concrete placed at least 2 feet below the adjacent undisturbed grade or at least 3 feet belowcompacted finished grade, an air-entraining admixture is not required unless the concrete will experiencefreezing conditions during construction.

The cementitious material must satisfy the following equation:

[(41 x UF) + (19 x F) + (11 x SL)]/TC 7.0

where:UF = silica fume, metakaolin, or UFFA, including the quantity in blended cement, lb/cu ydF = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, including the quantity in

blended cement, lb/cu yd. F is equivalent to the sum of FA and FB as defined in section 90-1.02I(2)(b).

SL = GGBFS, including the quantity in blended cement, lb/cu ydTC = total quantity of cementitious material used, lb/cu yd

90-1.02I(2)(b) Concrete Exposed to Deicing ChemicalsSection 90-1.02I(2)(b) applies to concrete specified in these specifications to be exposed to deicingchemicals.

The specifications for SCM content in section 90-1.02B(3) and the equation in section 90-1.02I(2)(a) donot apply.

The cementitious material must be composed of any combination of portland cement and at least 1 SCMsatisfying the following equation:

Equation 1:


REVISION 0


[(25 x UF) + (12 x FA) + (10 x FB) + (6 x SL)]/TC X

The SCM must satisfy the following equations:

Equation 2:

4 x (FA + FB)/TC 1.0

Equation 3:

(10 x UF)/TC 1.0

Equation 4:

2 x (UF + FA + FB + SL)/TC 1.0

The concrete mix design must satisfy the following equation:

Equation 5:

27 x (TC - MC)/MC 5.0

where:UF = silica fume, metakaolin, or UFFA, including the quantity in blended cement, lb/cu yd. If UF is

used, the quantity of UF must be at least 5 percent.FA = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content of

up to 10 percent, including the quantity in blended cement, lb/cu yd. If FA is used, the quantityof FA must be at least 15 percent.

FB = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content ofgreater than 10 percent and up to 15 percent, including the quantity in blended cement, lb/cuyd. If FB is used, the quantity of FB must be at least 15 percent.

SL = GGBFS, including the quantity in blended cement, lb/cu ydTC = total quantity of cementitious material, lb/cu ydX = 1.8 for innocuous aggregate, 3.0 for all other aggregateMC = minimum quantity of cementitious material specified, lb/cu yd

90-1.02J Curing CompoundCuring compound water loss must not exceed 0.15 kg/m2 in 24 hours when tested under California Test534.


90-1.03B Curing Concrete90-1.03B(1) GeneralCure newly placed concrete by the method specified for the type of work involved.

Cure mortar and grout by keeping the surface damp for 3 days.

90-1.03B(2) Water MethodThe water method must consist of keeping the concrete continuously wet by applying water for a curingperiod of at least 7 days after the concrete is placed.

You may use cotton mats, rugs, carpets, or earth or sand blankets as a curing medium to retain themoisture during the curing period.


REVISION 0


For curing structures, you may use a curing medium consisting of white opaque polyethylene sheetingextruded onto burlap. The polyethylene sheeting must have a minimum thickness of 4 mils and must beextruded onto 10-ounce burlap.

For curing columns, you may use a curing medium consisting of polyethylene sheeting with a minimumthickness of 10 mils achieved in a single layer of material.

Keep the concrete surface damp by applying water with an atomizing nozzle that forms a mist and not aspray until the surface is covered with the curing medium. Do not apply the water under pressure directlyon the concrete or allow the water to flow over or wash the concrete surface. At the end of the curingperiod, remove the curing medium.

If you use polyethylene sheeting or polyethylene sheeting on burlap as a curing medium:

1. Secure the sheeting and the sheeting joints as necessary to retain moisture2. Keep the sheeting within 3 inches of the concrete at all points along the surface being cured3. Monitor the concrete temperature during curing4. Discontinue the use of these curing media if the concrete temperature cannot be maintained below

140 degrees F

90-1.03B(3) Curing Compound Method90-1.03B(3)(a) GeneralThe curing compound method must consist of uniformly spraying the concrete surfaces exposed to the airwith a curing compound.

90-1.03B(3)(b) MaterialsThe curing compound must comply with the requirements shown in the following table for the curingcompound number specified:

Curingcompound no. ASTM C 309 classification

1 Pigmented, Type 2, Class Ba

2 Pigmented, Type 2, Class B3 Pigmented, Type 2, Class A4 Nonpigmented, Type 1, Class B5 Nonpigmented, Type 1, Class A6 Nonpigmented with fugitive dye, Type 1-D, Class A

aThe resin type must be poly-alpha-methylstyrene. The infrared scanfor the dried vehicle must match the scan on file at Caltrans.

If no curing compound number is specified, use any of the curing compounds shown in the table above.

The curing compound must be manufactured to:

1. Remain sprayable at temperatures above 40 degrees F2. Control sagging, pigment settling, leveling, and de-emulsification3. Maintain the specified properties for at least 1 year

Pigmented curing compounds must be manufactured such that the pigment does not settle badly, cake orthicken in the container, or become granular or curdled.

Settlement of pigment must be a thoroughly wetted, soft, mushy mass allowing the complete and easyvertical penetration of a paddle. Settled pigment must be easily predisposed, with minimum resistance tothe sideways manual motion of the paddle across the bottom of the container, to form a smooth, uniformproduct of the proper consistency.

Do not dilute or alter the curing compound after manufacture.


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The curing compound must be packaged in clean 274-gallon totes, 55-gallon barrels, or 5-gallon pails, ormust be supplied from a suitable storage tank located at the job site. The containers must comply with 49CFR 171–180. The 274-gallon totes and 55-gallon barrels must have removable lids and airtightfasteners. The 5-gallon pails must be round and have standard full open head and bail. Do not use lidswith bungholes.

Containers must be filled in a way that prevents skinning.

Steel containers and lids must be lined with a coating that prevents destructive action by the compound orchemical agents in the air space above the compound. The coating must not come off the container or lidas skins.

Plastic containers and lids must not react with the curing compound.

Label each curing compound container with:

1. Manufacturer's name2. ASTM C 309 classification3. Batch number4. Volume5. Date of manufacture6. Volatile organic compound content7. Warning that curing compound containing pigment must be well stirred before using8. Precautions concerning the handling and application of curing compound shown in compliance with 8

CA Code of Regs §§ 1500–1938 and 3200–61849. Statement that the contents fully comply with State air pollution control rules and regulations

90-1.03B(3)(c) MixingBefore using a curing compound, completely redisperse settled or separated solids in containers, excepttanks, by mixing at low speed in compliance with these specifications and the manufacturer's instructions.Mix manually using a paddle or mix using a mixing blade driven by a drill motor at low speed. Mixingblades must be the type used for mixing paint.

Keep on-site storage tanks clean and free of contaminants. Each tank must have a permanent systemthat completely redisperses settled material without introducing air or other foreign substances.

At the time of use, compounds containing pigments must be thoroughly mixed. Use a paddle to loosen allsettled pigment from the container bottom and use a power-driven agitator to disperse the pigmentuniformly throughout the vehicle.

Agitation must not introduce air or other foreign substances into the curing compound.

90-1.03B(3)(d) ApplicationApply the curing compound at a nominal rate of 150 sq ft/gal.

At any point, the application rate must be within 50 sq ft/gal of the nominal rate. The average applicationrate must be within ±25 sq ft/gal of the nominal rate when tested under California Test 535. Apply thecuring compound such that there are no runs, sags, thin areas, skips, or holidays.

Apply the curing compound using power-operated spraying equipment with an operational pressure gageand a means of controlling the pressure. The Engineer may allow hand spraying for small and irregularareas that, in the Engineer's opinion, are not reasonably accessible to power-operated sprayingequipment.

Apply the curing compound to the concrete after finishing the surface, immediately before the moisturesheen disappears from the concrete surface but before drying shrinkage or craze cracks start to appear.

If the concrete surface cracks or dries, immediately and continually apply water with an atomizing nozzleas specified in section 90-1.03B(2) until application of the curing compound is resumed or started. Do notapply the curing compound over freestanding water.


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If the film of curing compound is damaged before the expiration of 7 days after the concrete is placed forstructures and 72 hours for pavement, immediately repair it with additional compound.

90-1.03B(4) Waterproof Membrane MethodThe waterproof membrane method must consist of:

1. Spraying the exposed finished concrete surfaces with water, using an atomizing nozzle that forms amist and not a spray, until the concrete has set

2. Placing the waterproof curing membrane immediately after spraying3. Keeping the membrane in place for at least 72 hours

The membrane must be sheeting material that complies with AASHTO M 171 for white reflectivematerials.

Use sheeting material of such a width as to completely cover the entire concrete surface. Cement thesheeting joints together securely such that the joints are waterproof. The joint seams must have at least a4-inch lap.

Securely weigh down the sheets by placing an earth bank on the sheet edges or by other means allowedby the Engineer.

If any portion of the sheets are damaged within 72 hours after being placed, immediately repair thedamaged portion by cementing new sheets into place.

Do not use a membrane that is no longer waterproof or has been damaged such that it is unfit for curingconcrete.

90-1.03B(5) Forms-In-Place MethodThe forms-in-place method must consist of curing formed concrete surfaces by keeping the forms inplace.

Keep the forms in place for at least 7 days after the concrete is placed, except keep the forms in place forat least 5 days for concrete members over 20 inches in least dimension.

The joints in the forms and the joints between the end of the forms and the concrete must be keptmoisture tight during the curing period. Reseal cracks in the forms and cracks between the forms and theconcrete using authorized methods.

90-1.03C Protecting ConcreteProtect the concrete from damage due to any cause, including rain, heat, cold, wind, your actions, andthe actions of others.

Do not place the concrete on frozen or ice-coated ground or subgrade or on ice-coated forms, reinforcingsteel, structural steel, conduits, precast members, or construction joints.

If it is raining, you must provide adequate protection against damage or you must stop placing theconcrete before the quantity of surface water is sufficient to damage the surface mortar or cause a flow orwash of the concrete surface.

90-2 MINOR CONCRETE90-2.01 GENERAL90-2.01A SummarySection 90-2 includes specifications for furnishing and protecting minor concrete.

90-2.01B DefinitionsReserved


REVISION 0


90-2.01C SubmittalsIf required by the following table, submit compressive strength test results with the mix design that verifythe minimum required compressive strength:

SCM Test submittal requiredFly ash used alone If portland cement content < 350 lb/cu ydGGBFS used alone If portland cement content < 250 lb/cu ydNatural pozzolan used alone If portland cement content < 350 lb/cu ydMore than 1 SCM AlwaysNOTE: Compressive strength tests must be performed by an ACI-certified technician.

Submit the concrete mix design before using the concrete in the work and before changing the mixproportions.

Submit a proposed combined aggregate grading. After authorization of the grading, the aggregatefurnished for minor concrete must comply with that grading.

If requested, submit periodic test reports of the aggregate grading furnished.

The Engineer may waive the specifications for gradation if the Engineer determines that furnishing agradation is not necessary for the type or quantity of concrete work to be constructed.

Before placing minor concrete from a source not previously used on the Contract, submit a certificate ofcompliance stating that the minor concrete to be furnished complies with the Contract requirements,including the specified minimum cementitious material content.

Submit a weighmaster certificate as an informational submittal with each load of ready-mixed concrete atthe concrete discharge location. The weighmaster certificate must show the date and time the load leftthe batching plant and, if hauled in a truck mixer or agitator, the time the mixing cycle started.

90-2.01D Quality Control and AssuranceSection 90-1.01D(5) and the specifications for uniformity in section 90-1.02A do not apply to minorconcrete.

The Engineer may perform tests and inspect the facilities, materials, and methods for producing the minorconcrete to ensure that it is of suitable quality for use in the work.

The Engineer verifies compliance with the specified cementitious material content by testing underCalifornia Test 518 for cement content. For testing purposes, SCM is considered to be cement. Adjust thebatch proportions as necessary to produce concrete having the specified cementitious material content.

90-2.02 MATERIALS90-2.02A GeneralReserved

90-2.02B Cementitious MaterialMinor concrete must contain at least 505 pounds of cementitious material per cubic yard.

90-2.02C AggregateSections 90-1.01C(2) and 90-1.02C do not apply to minor concrete.

The aggregate must be clean and free from deleterious coatings, clay balls, roots, and other extraneousmaterial.

The maximum aggregate size must not be larger than 1-1/2 inches or smaller than 3/4 inch.

You may use crushed concrete and reclaimed aggregate if they comply with the specifications foraggregate.


REVISION 0


90-2.02D WaterSection 90-1.02D does not apply to minor concrete.

Water used for washing, mixing, and curing must be free from oil, salts, and other impurities that woulddiscolor or etch the surface or have an adverse affect on the concrete quality.

90-2.02E ProductionSections 90-1.02F, 90-1.02G(1), 90-1.02G(2), 90-1.02G(3), and 91-1.02G(4) do not apply to minorconcrete.

Store, proportion, mix, transport, and discharge the cementitious material, water, aggregate, andadmixtures in compliance with recognized standards of good practice that result in thoroughly anduniformly mixed concrete suitable for the intended use. Recognized standards of good practice areoutlined in various industry publications, such as those issued by ACI, AASHTO, or the Department.

Use a quantity of water that produces concrete with a consistency that complies with section 90-1.02G(6).Do not add water during hauling or after arrival at the delivery point unless allowed by the Engineer.

Discharge ready-mixed concrete from the transport vehicle while the concrete is still plastic and beforestiffening occurs. Take whatever action is necessary to eliminate quick stiffening, except do not addwater.

Conditions contributing to quick stiffening are:

1. Elapsed time of 1.5 hours in agitating hauling equipment or 1 hour in nonagitating hauling equipment2. More than 250 revolutions of the drum or blades after introduction of the cementitious material to the

aggregates3. Concrete temperature over 90 degrees F

The mixing time in a stationary mixer must be at least 50 seconds and no more than 5 minutes.

The minimum required revolutions at mixing speed for transit-mixed concrete must be at least thatrecommended by the mixer manufacturer and must be increased as needed to produce thoroughly anduniformly mixed concrete.

If you add a high-range water-reducing admixture to the concrete at the job site, the total revolutions mustnot exceed 300.

90-2.03 CONSTRUCTIONMaintain a concrete temperature of at least 40 degrees F for 72 hours after placing.

90-3 RAPID STRENGTH CONCRETENot Used

90-4 PRECAST CONCRETE90-4.01 GENERAL90-4.01A SummarySection 90-4 includes specifications for furnishing and curing PC concrete.

The specifications for shrinkage in section 90-1.02A do not apply.


90-4.01C SubmittalsSubmit a certificate of compliance for the cementitious material used in PC concrete products that youpurchase. The certificate must be signed by the PC concrete product manufacturer.

Submit expansion test data under section 90-4.02, if required.


REVISION 0


90-4.01D Quality Control and AssuranceFor PC concrete that is steam cured:

1. Determine the concrete compressive strength from test cylinders that have been handled and storedunder California Test 540, Method 3

2. Engineer evaluates the compressive strength based on individual tests representing specific portionsof production

3. Concrete designated by compressive strength is acceptable if its compressive strength reaches thedescribed 28-day compressive strength in no more than the maximum number of days specified orallowed after the concrete is cast

If PC concrete is manufactured at an established PC concrete plant, a trial batch and prequalification ofthe materials, mix proportions, mixing equipment, and procedures under section 90-1.01D(5)(b) are notrequired.

90-4.02 MATERIALSYou may use Type III portland cement in PC concrete.

The specifications for SCM content in section 90-1.02B(3) do not apply to PC concrete.

For PC concrete, the SCM content must comply with one of the following:

1. Any combination of portland cement and SCM satisfying the following equation:

Equation 1:

[(25 x UF) + (12 x FA) + (10 x FB) + (6 x SL)]/TC X

where:UF = silica fume, metakaolin, or UFFA, including the quantity in blended cement, lb/cu ydFA = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content of

up to 10 percent, including the quantity in blended cement, lb/cu ydFB = natural pozzolan or fly ash complying with AASHTO M 295, Class F or N, with a CaO content of

greater than 10 percent and up to 15 percent, including the quantity in blended cement, lb/cuyd

SL = GGBFS, including the quantity in blended cement, lb/cu ydTC = total quantity of cementitious material, lb/cu ydX = 0.0 for innocuous aggregate, 3.0 for all other aggregate

2. 15 percent Class F fly ash with at least 48 oz of LiNO3 solution added per 100 lb of portland cement.The CaO content of the fly ash must not exceed 15 percent.

3. Any combination of SCM and portland cement for which the expansion of cementitious material andaggregate does not exceed 0.10 percent when tested under ASTM C 1567. Submit test data witheach mix design. Test data authorized by the Department no more than 3 years before the 1st day ofthe Contract is authorized for the entire Contract. The test data must be for the same concrete mixand must use the same materials and material sources to be used on the Contract.

90-4.03 CONSTRUCTIONCure PC concrete using steam curing or any of the methods specified in section 90-1.03B. Cure for theminimum time specified for each method or until the concrete reaches its design strength, whichever isless.

Steam curing must comply with the following:

1. After placing the concrete, hold it for a 4-hour minimum presteaming period. If the ambient airtemperature is below 50 degrees F, apply steam during the presteaming period to hold the airsurrounding the concrete at a temperature of from 50 to 90 degrees F.


REVISION 0


2. To prevent moisture loss on the exposed surfaces during the presteaming period, cover the concreteas soon as possible after casting or keep the exposed surfaces wet by fog spray or wet blankets.

3. Enclosures for steam curing must allow free circulation of steam around the concrete and must beconstructed to contain the live steam with a minimum moisture loss. The use of tarpaulins or similarflexible covers is allowed if they are kept in good repair and secured in such a way that prevents theloss of steam and moisture.

4. Steam at the jets must be at low pressure and in a saturated condition. Steam jets must not impingedirectly on the concrete, test cylinders, or forms. During application of the steam, the temperature risewithin the enclosure must not exceed 40 degrees F per hour. The curing temperature throughout theenclosure must not exceed 150 degrees F and must be maintained at a constant level for the timenecessary to develop the required transfer strength. Cover control cylinders to prevent moisture lossand place them in a location where the temperature is representative of the average enclosuretemperature.

5. Use a minimum of 1 temperature recording device per 200 feet of continuous bed length for checkingthe temperature. Temperature recording devices must provide an accurate, continuous, permanentrecord of the curing temperature.

6. Detension the concrete in pretension beds immediately after the steam curing is completed while theconcrete and forms are still warm, or maintain the temperature under the enclosure above 60 degreesF until the stress is transferred to the concrete.

7. Curing is complete at the end of the steam curing cycle.

91 PAINT91-1 GENERAL

91-1.01 GENERALSection 91-1 includes general specifications for furnishing paints used for highway construction.

91-1.02 SAMPLING AND TESTINGThe Department tests samples of paint taken from the source. Do not use paint until authorized.

91-1.03 MANUFACTURING AND PACKAGINGPaint must be manufactured ready for application. Do not add materials such as thinner aftermanufacture.

Paint containers must be:

1. New2. Round3. No more than 6 gallons in capacity4. Standard full open head with bails5. Nonreactive with contents6. Equipped with compatible gaskets7. Free of bungholes in the lids8. Labeled with:

8.1. State Specification number if described8.2. Manufacturer's name, product number, and batch number8.3. Date of manufacture8.4. Precautions required by 8 CA Code of Regs §§ 1501–1756 and §§ 3200–3206 concerning the

handling and application of paint

91-1.04 MATERIALSPaint must be homogeneous and free of contaminants. Paint must be smooth and any settled pigmentmust be soft and easily dispersed before using.

Paint must retain the properties that affect its application, adhesion, and curing for at least 1 year after thedate of manufacture.


REVISION 0


If a paint is designated by a State Specification number, you may obtain the paint specification from theDepartment.

Zinc-rich primer must be on the Authorized Material List.

91-2 PAINTS FOR METAL91-2.01 GENERALSection 91-2 includes specifications for furnishing paint for metal.

91-2.02 EXTERIOR GRADE LATEX PAINTExterior grade latex paint must be approved by the manufacturer of the zinc rich primer.

Exterior grade latex paint must comply with SSPC-Paint 24 and the following:

1. When tested for 800 hours under ASTM D4587, test cycle 2, visible color change in the finish coatmust not occur

2. Vehicle must be an acrylic or modified acrylic copolymer with a minimum of necessary additives

92 ASPHALTSNot Used

93 LIQUID ASPHALTSNot Used

94 ASPHALTIC EMULSIONSNot Used

95 EPOXY95-1 GENERAL

95-1.01 DESCRIPTIONSection 95-1 includes general specifications for mixing and applying epoxy for highway construction.

Furnish epoxy as 2 components and mix them together at the job site.

The 2 proportioned epoxy components define a kit when packaged together.

95-1.02 SAMPLING AND TESTINGSubmit a certificate of compliance for epoxy.

95-1.03 PACKAGING, LABELING, AND STORINGEach component must be packaged in a container of a size that complies with the epoxy manufacturer'sinstructions for proportions.

Component containers must be sealed and not leak. Containers must not react with components.

The container for each component must be clearly labeled by the epoxy manufacturer with the followinginformation:

1. ASTM C 881/C 881M class and type2. Component designation, A or B3. Manufacturer's name4. Manufacture date5. Batch number6. Expiration date7. Directions for use8. Warnings or precautions required by State and federal laws and regulations


REVISION 0


Store components at temperatures greater than 35 degrees F.

95-1.04 DIRECTION FOR USEMix and apply the epoxy under the manufacturer's instructions.

Do not use a component if any of the following occur:

1. Evidence of crystallization or thickening2. Settled pigments that cannot be readily dispersed with a paddle3. Component is older than the manufacturer's recommended expiration date

Thoroughly stir each component before mixing a kit. Do not mix partial kits. Do not add solvents.

Automatic mixing equipment must have positive displacement pumps and be capable of metering a 2-component mix in the specified ratio ± 5 percent by volume of either component.

Mix the 2 components until no trace of black or white streaks is present in the mixed epoxy.

Clean surfaces to receive the epoxy of rust, paint, grease, asphalt, loose, and deleterious material. Applythe epoxy and place materials to be bonded before the epoxy starts to thicken. Do not use epoxy that hasexceeded its working life.

95-2 TYPES OF EPOXIES95-2.01 EPOXY BINDEREpoxy binder must be low viscosity epoxy formulated primarily for use in:

1. Making HS epoxy concrete and epoxy mortar2. Pressure grouting cracks in concrete

For load bearing applications, the epoxy must comply with ASTM C 881/C 881M, Type IV, Grade 1, ClassB or C.

For nonload bearing applications, the epoxy must comply with ASTM C 881/C 881M, Type I, Grade 1,Class B or C.

Use Class B whenever the surface temperature is from 40 to 60 degrees F. Use Class C whenever thesurface temperature is above 60 degrees F.

Thoroughly mix the components before adding aggregate if the epoxy is used as binder for HS epoxyconcrete or epoxy mortar. The mix proportions must be 1 part epoxy to 4 parts aggregate by volume.Aggregate must be clean and have a moisture content of not more than 0.50 percent when tested underCalifornia Test 226. Prime surfaces with epoxy immediately before placing epoxy concrete or mortar.

95-2.02 RESERVED95-2.03 EPOXY ADHESIVE FOR BONDING FRESHLY MIXED CONCRETE TO HARDENEDCONCRETEEpoxy adhesive for bonding freshly mixed concrete to hardened concrete must comply with ASTM C881/C 881M, Type V, Grade 2, Class B or C.

Use Class B whenever the surface temperature is from 40 to 60 degrees F or if a faster cure is required.Use Class C whenever the surface temperature is above 60 degrees F.

Coat the blast-cleaned concrete surface with epoxy using a brush or roller. Place freshly mixed concretewhile the epoxy is tacky. Apply a new coat of epoxy if the epoxy sets.

95-2.04 RAPID SET EPOXY ADHESIVE FOR PAVEMENT MARKERSRapid set epoxy adhesive for bonding pavement markers to concrete and HMA must comply with ASTMC 881/C 881M, Type IV, Grade 3, Class B or C, except the gel time may be less than 30 minutes.


REVISION 0



When tested under California Test 434, epoxy must comply with the requirements for the propertiesshown in the following table:

Rapid Set Epoxy Adhesive For Pavement MarkersProperty Requirement

Gel time, minutes, maximum, at 77 °F 30Bond strength to concrete, minutes, maximum to reach not lessthan 200 psi

at 77 ± 2 °F 35at 50 ± 2 °F 45

Slant shear strength, minimum, psi2 days at 77 ± 2 °F 1,00014 days at 77 ± 2 °F, plus water soak 1,500

Tensile adhesion and cohesion, minimum, psiCeramic marker bottom 700Ceramic marker bottom, including post cure 700Retroreflective pavement marker bottom 500

Color of mixed epoxy grayGlass transition temperaturea, Tg, minimum 86 °FaBefore testing samples must be conditioned at 77 °F for 24 hours under ASTMD 4065

95-2.05 STANDARD SET EPOXY ADHESIVE FOR PAVEMENT MARKERSStandard set epoxy adhesive for bonding pavement markers to concrete and HMA must comply withASTM C 881/C 881M, Type IV, Grade 3, Class B or C.


When tested under California Test 434, epoxy must comply with the requirements for the propertiesshown in the following table:

Standard Set Epoxy Adhesive For Pavement MarkersProperty Requirement

Bond strength to concrete, time, maximum to reach not lessthan 200 psi

at 77 ± 2 °F 3.5 hoursat 55 ± 2 °F 24 hours

Slant shear strength, minimum, psi2 days at 77 ± 2 °F 1,00014 days at 77 ± 2 °F, plus water soak 1,500

Tensile adhesion and cohesion, minimum, psiCeramic marker bottom 700Ceramic marker bottom, including post cure 700Reflective pavement marker bottom 500

Color of mixed components grayGlass transition temperaturea, Tg, minimum 86 °FaBefore testing samples must be conditioned at 77 °F for 24 hours underASTM D 4065


REVISION 0


95-2.06–95-2.08 RESERVED95-2.09 EPOXY SEALANT FOR INDUCTIVE LOOPSThe epoxy for sealing inductive loops and leads imbedded in HMA and concrete must comply with ASTMC 881/C 881M, Type I, Grade 2.

When tested under California Test 434, epoxy sealant must comply with the values for the propertiesshown in the following table:

Epoxy Sealant for Inductive LoopsProperty Value

Tensile strengtha, minimum, psi 400Elongationa, minimum, % 90Shore D hardnessa, minimum 45aTest on a 0.125-inch cast sheet, cured 18 hours at 77 °F plus 5hours at 160 °F

95-2.10 RESERVED95-2.11 EPOXY RESIN ADHESIVE FOR PRESSURE INJECTION GROUTING OF CONCRETEPAVEMENTEpoxy resin adhesive for injection grouting of concrete pavement must comply with the values for theproperties when tested as shown in the following table:

Epoxy Resin Adhesive for Injection Grouting of Concrete PavementProperty California Test 434 Value

Brookfield viscosity, no. 3 spindle at 20 rpm,poise, maximum, at 77 °F

Part 4, "Brookfield Viscosity" 0.9

Gel time, minutes Part 1, "Gel Time" 2–15Slant shear strength on dry concrete, minimum,psi, after 4 days of cure in air at 77 ± 2 °F

Part 5, "Slant ShearStrength"a

3,000

Slant shear strength on wet concrete, minimum,psi, after 4 days of cure in air at 77 ± 2 °F

Part 5, "Slant ShearStrength"a

1,700

Tensile strength, minimum, psi Part 7, "Tensile Strength andElongation" except test after4 days of cure at 77 ± 2 °F

4,500

Elongation, %, maximum Part 7, "Tensile Strength andElongation" except test after4 days of cure at 77 ± 2 °F

10

aFor slant shear strength on concrete, procedures B-1 and B-5 do not apply. Testing on dryconcrete must comply with item 2 listed in the following. Testing on wet concrete must complywith both of the following:

1. Soak blocks in water for 24 hours at 77 ± 2 °F. Remove and wipe off excess water.2. Apply a coat of epoxy 0.010 inch thick to each diagonal surface. Place 4 pieces of shimstock on 1 block to control final film thickness. Shim stock pieces must be 0.12 by 0.125inch and 0.012 inch thick. Before pressing the coated surfaces together, leave the blockssuch that the coated surfaces are horizontal until the epoxy reacts slightly to preventexcessive flow.

96–98 NOT USED

DIVISION XI BUILDING CONSTRUCTION99 BUILDING CONSTRUCTION

Not Used