Bridge deck preservation procedures for the Arizona Department of Transportation

              BRIDGE DECK PRESERVATION
PROCEDURES FOR THE
ARIZONA DEPARTMENT OF
TRANSPORTATION
Final Report 520
Prepared by:
J. E. Bruinsma and D. G. Peshkin
Applied Pavement Technology, Inc.
3010 Woodcreek Drive, Suite J
Downers Grove, Illinois 60515
February 2006
Prepared for:
Arizona Department of Transportation
206 South 17th Avenue
Phoenix, Arizona 85007
in cooperation with
U.S. Department of Transportation
Federal Highway Administration
DISCLAIMER
The contents of this report reflect the views of the authors who are responsible for the facts and
the accuracy of the data presented herein. The contents do not necessarily reflect the official
views or policies of the Arizona Department of Transportation or the Federal Highway
Administration. This report does not constitute a standard, specification, or regulation. Trade or
manufacturers' names which may appear herein are cited only because they are considered
essential to the objectives of the report. The U.S. Government and the State of Arizona do not
endorse products or manufacturers.
Technical Report Documentation Page
1. Report No.
FHWA-AZ-06-520
2. Government Accession No. 3. Recipient's Catalog No.
5. Report Date
February 2006
4. Title and Subtitle
BRIDGE DECK PRESERVATION PROCEDURES FOR THE
ARIZONA DEPARTMENT OF TRANSPORTATION 6. Performing Organization Code
7. Authors
J. E. Bruinsma and D. G. Peshkin
8. Performing Organization Report No.
9. Performing Organization Name and Address 10. Work Unit No.
Applied Pavement Technology, Inc.
3010 Woodcreek Drive, Suite J
Downers Grove, Illinois 60515
11. Contract or Grant No.
SPR-PL-1(59) ITEM 520
13.Type of Report & Period Covered
Final Report
12. Sponsoring Agency Name and Address
Arizona Department of Transportation
206 S. 17th Avenue
Phoenix, Arizona 85007
14. Sponsoring Agency Code
15. Supplementary Notes
Prepared in cooperation with the U.S. Department of Transportation, Federal Highway Administration
16. Abstract
The primary objective of this project is to identify several common bridge deck maintenance activities that are
performed by contract, review the current Arizona Department of Transportation (ADOT) specifications for
those maintenance activities, modify the specifications where appropriate to reflect current accepted practice,
and to serve as a model to guide future efforts at updating specifications.
To complete the project, all of ADOT’s bridge deck maintenance specifications were reviewed. The following
repairs were identified for further evaluation:
• Temporary repair of expansion joints.
• Minor collision damage repair of concrete I-beam girders.
• Hole in deck repair (with and without asphalt overlay).
• Bridge railing repair (concrete and aluminum).
Bridge preservation specifications from other agencies were then collected and reviewed. This led to the
selection of two treatments to develop new draft specifications:
• Bridge Deck Repair: Full-Depth Patch.
• Prestressed Concrete I-Beam: Minor Repair by Patching and Epoxy Resin Base Adhesive Injection.
Draft specifications were developed and submitted to ADOT for review and possible implementation, thereby
completing the project.
17. Key Words
Bridge deck repair; bridge maintenance;
specifications; full-depth patch; prestressed
concrete I-beam repair
18. Distribution Statement
Document is available to the U.S.
Public through the National
Technical Information Service,
Springfield, Virginia, 22161
19. Security Classification
Unclassified
20. Security Classification
Unclassified
21. No. of Pages
40
22. Price
23. Registrant's Seal
SI* (MODERN METRIC) CONVERSION FACTORS
APPROXIMATE CONVERSIONS TO SI UNITS APPROXIMATE CONVERSIONS FROM SI UNITS
Symbol When You Know Multiply By To Find Symbol Symbol When You Know Multiply By To Find Symbol
LENGTH LENGTH
in inches 25.4 millimeters mm mm millimeters 0.039 inches in
ft feet 0.305 meters m m meters 3.28 feet ft
yd yards 0.914 meters m m meters 1.09 yards yd
mi miles 1.61 kilometers km km kilometers 0.621 miles mi
AREA AREA
in2 square inches 645.2 square millimeters mm2 mm2 square millimeters 0.0016 square inches in2
ft2 square feet 0.093 square meters m2 m2 square meters 10.764 square feet ft2
yd2 square yards 0.836 square meters m2 m2 square meters 1.195 square yards yd2
ac acres 0.405 hectares ha ha hectares 2.47 acres ac
mi2 square miles 2.59 square kilometers km2 km2 square kilometers 0.386 square miles mi2
VOLUME VOLUME
fl oz fluid ounces 29.57 milliliters mL mL milliliters 0.034 fluid ounces fl oz
gal gallons 3.785 liters L L liters 0.264 gallons gal
ft3 cubic feet 0.028 cubic meters m3 m3 cubic meters 35.315 cubic feet ft3
yd3 cubic yards 0.765 cubic meters m3 m3 cubic meters 1.308 cubic yards yd3
NOTE: Volumes greater than 1000L shall be shown in m3.
MASS MASS
oz ounces 28.35 grams g g grams 0.035 ounces oz
lb pounds 0.454 kilograms kg kg kilograms 2.205 pounds lb
T short tons (2000lb) 0.907 megagrams
(or “metric ton”)
mg
(or “t”)
mg
(or “t”)
megagrams
(or “metric ton”)
1.102 short tons (2000lb) T
TEMPERATURE (exact) TEMPERATURE (exact)
ºF Fahrenheit
temperature
5(F-32)/9
or (F-32)/1.8
Celsius temperature ºC ºC Celsius temperature 1.8C + 32 Fahrenheit
temperature
ºF
ILLUMINATION ILLUMINATION
fc foot candles 10.76 lux lx lx lux 0.0929 foot-candles fc
fl foot-Lamberts 3.426 candela/m2 cd/m2 cd/m2 candela/m2 0.2919 foot-Lamberts fl
FORCE AND PRESSURE OR STRESS FORCE AND PRESSURE OR STRESS
lbf poundforce 4.45 newtons N N newtons 0.225 poundforce lbf
lbf/in2 poundforce per
square inch
6.89 kilopascals kPa kPa kilopascals 0.145 poundforce per
square inch
lbf/in2
SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380
TABLE OF CONTENTS
INTRODUCTION .....................................................................................................................1
PROJECT OBJECTIVES..........................................................................................................1
PROJECT APPROACH ............................................................................................................1
Review ADOT Specifications....................................................................................................2
Collect and Review Bridge Preservation Specifications from Other Agencies.........................2
Develop Draft Specifications.....................................................................................................2
RECOMMENDATIONS...........................................................................................................3
APPENDIX A: SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES................................................................................................5
APPENDIX B: PROPOSED SPECIFICATION FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING AND EPOXY-RESIN BASE
ADHESIVE INJECTION........................................................................................................13
APPENDIX C: PROPOSED CHECKLIST FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING
AND EPOXY-RESIN BASE ADHESIVE INJECTION........................................................21
APPENDIX D: PROPOSED SPECIFICATION FOR BRIDGE DECK REPAIR: FULL-DEPTH
PATCH.......................................................................................................................27
REFERENCES ........................................................................................................................35
1
INTRODUCTION
A significant number of Arizona Department of Transportation’s (ADOT's) bridges are
20 years and older. As these bridges age, they are deteriorating from a wide range of
forces including load-related damage and damage due to environmental effects such as
freeze thaw action, sulfate attack, ASR reactivity, and so on. And as they deteriorate, the
need for repairs to ADOT’s structures is becoming increasingly common. While
historically ADOT’s maintenance crews have performed many bridge repairs, bridge
maintenance activities are becoming increasingly complex, and some require the use of
specialized materials or equipment that are not available to ADOT. As such, this work
ends up being performed under on-call contracts.
ADOT is interested in ensuring that all bridge maintenance work is performed to the
highest possible standards. This can be accomplished by verifying that the specifications
that apply to bridge maintenance are comprehensive, up-to-date, and reflect the current
state of the practice.
PROJECT OBJECTIVES
The primary objective of this project is to identify several common bridge deck
maintenance activities that are performed by on-call contract, review the current ADOT
specifications for those maintenance activities, and recommend modifications to the
specifications where appropriate to reflect current accepted practice. This project is
intended to serve as a demonstration of the feasibility of developing such specifications
for Arizona and not as a process which results in the development of a comprehensive set
of new bridge maintenance guidelines. As such, the goal is to develop one or two
specifications to serve as a model for future efforts.
PROJECT APPROACH
The approach taken to accomplish the project objectives consists of the following tasks:
• Review ADOT specifications.
• Collect and review bridge preservation specifications from other agencies.
• Develop draft specifications.
The work accomplished in each of these tasks is described in greater detail in the
remainder of this summary.
2
Review ADOT Specifications
ADOT provided a list of bridge preservation activities which might be performed under
on-call contract. These preservation activities include the following:
• Temporary repair of expansion joints.
• Minor collision damage repair of concrete I-beam girders.
• Hole in deck repair (with and without asphalt overlay).
• Bridge railing repair (concrete and aluminum).
To begin this project, the existing ADOT Standard Specifications and Supplemental (or
Special) Specifications were reviewed to determine the applicable sections for the
preservation items. Although the focus of subsequent efforts was to consolidate existing
information and obtain relevant additional information for only one to two of the
preservation items, material was collected on all of the preservation activities to compare
available specifications.
Collect and Review Bridge Preservation Specifications from Other Agencies
A survey of state highway agency (SHA) bridge maintenance practices was conducted as
part of this project. Maintenance engineers in SHAs around the country were asked to
summarize the type of bridge maintenance work that is done both by contract and by
agency forces. The results of this survey are summarized in Appendix A (Summary of
State Highway Agencies’ Bridge Deck Maintenance Practices). One product of this
survey is the identification of SHAs that have developed bridge preservation procedures
that are of interest to this project.
The Federal Highway Administration’s website was also searched for documents on
bridge preservation activities. This site primarily was useful in identifying which SHAs
might have relevant documents of value to this project, particularly supplemental
specifications. The result is that documents were obtained from a number of SHAs,
including California, Connecticut, Alabama, North Carolina, Ohio, Illinois, Rhode Island,
Oregon, Pennsylvania, and Michigan. Materials collected included standard
specifications and supplemental specifications relating to bridge preservation activities.
The collected materials were then reviewed to determine the state-of-the-practice for the
provided bridge preservation activities.
Develop Draft Specifications
The applicable portions of the ADOT Standard Specifications and Supplemental
Specifications were used as the basis for developing the proposed draft specifications. In
addition to ADOT’s own specifications, the results of the SHA specifications review
were used to supplement the draft specifications.
3
The result was the development of two specifications from the initial four preservation
activities, as identified below:
• Bridge Deck Repair: Full-Depth Patch
This specification covers deck slab repairs requiring removal and replacement to
the full depth of the deck (hole in deck). It includes (but is not necessarily limited
to) the following activities: bituminous surface removal and replacement; removal
and disposal of deteriorated concrete; constructing false work to support forms;
constructing forms; cleaning and repair of the existing reinforcement steel, where
required; cleaning and preparing of the bonding surface; and placing new
concrete.
• Prestressed Concrete I-Beam: Minor Repair by Patching and Epoxy Resin Base
Adhesive Injection
This specification addresses the repair of minor spalling and cracking in
prestressed concrete I-beams. This specification includes (but is not necessarily
limited to) the following activities: removal and disposal of damaged or
deteriorated concrete; cleaning and preparing of the bonding surface; cleaning of
the existing reinforcement steel; furnishing and injecting epoxy-resin base
adhesives; constructing falsework to support forms, where required; constructing
forms; and placing new concrete.
These two draft specifications were submitted to ADOT in January 2005, effectively
completing the project. These are included as Appendix B (Proposed Specification for
Prestressed Concrete I-Beam: Minor Repair by Patching and Epoxy-Resin Base Adhesive
Injection) and Appendix D (Proposed Specification for Bridge Deck Repair: Full-Depth
Patch). For the prestressed concrete I-beam specification, a draft checklist that could be
used by inspectors or foremen overseeing this type of activity was also developed and
submitted to provide an example of additional documentation that can be included in a
bridge maintenance manual to assist with ensuring the work is completed properly. That
checklist is included as Appendix C (Proposed Checklist for Prestressed Concrete I-Beam:
Minor Repair by Patching and Epoxy-Resin Base Adhesive Injection).
RECOMMENDATIONS
The documents prepared in this project constitute draft specifications. Ultimately, there
are several steps that need to be taken to turn draft specifications into revised and adopted
agency specifications.
1. Carry out an internal review of the proposed specification, including
representatives from Bridge and Maintenance Groups. If applicable, develop a
revised specification based on the feedback.
4
2. Carry out several trial repairs based on the draft specifications. Collect feedback
from those doing the repairs.
3. Identify lessons learned from the trial repairs, and develop modified specifications
if applicable.
4. When the draft specification is finalized, develop a checklist to accompany the
bridge maintenance activity.
5. Prepare a brief (1 to 2-hour) workshop that can be used to train Maintenance
personnel on the new specification.
6. Repeat this process for other repairs that can be made by Maintenance personnel.
5
APPENDIX A
SUMMARY OF STATE HIGHWAY AGENCIES’
BRIDGE DECK MAINTENANCE PRACTICES
6
7
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
Arkansas Jim Barnett 501-569-
2231
State State crews perform deck
patching, crack sealing, and joint
repairs. Maintenance work is
performed primarily based upon
experience of crews. Contractors
used for rehabilitation work.
California Larry Orcutt 916-654-
5849
Both State crews have capabilities of
doing work and will work on
small projects. Contractors work
on projects with large quantities
of repair work. The state has
written specifications to cover
repair work.
Connecticut Franco
Liberatore
860-594-
2626
Both State crews perform deck
patching, crack sealing, and joint
repair work. The State has a 2-
year “as needed” contract to allow
a contractor to perform work
when State crews cannot get work
completed, but they usually don’t
require contractor work. They
have a maintenance manual for
repair work.
Florida Sharon
Holmes
850-488-
8814
State Maintenance is performed by area
maintenance yards in each
District. Bridge Maintenance and
Repair Manual covers
maintenance work performed by
crews.
Illinois Dave
Johnson
217-782-
7231
Contractor Routine maintenance work is
performed by contractors.
Maintenance work includes deck
patching, crack sealing, and joint
repairs. State crews perform
temporary or emergency work.
Specifications cover work items.
8
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES (Continued)
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
Indiana Mike
Bowman
317-232-
5508
Both Minor patching and crack sealing
are performed by District crews.
Extensive patching and joint repairs
are conducted by contractors.
Maintenance work is covered by
general specifications, but they do
not have a specific manual for
maintenance work.
Kentucky Don Herd 502-564-
4556
State State crews perform deck patching
and joint repairs, but do not
typically crack seal. Work is
performed based upon crew
experience; specifications exist for
materials and anticipated resource
requirements.
Louisiana Karl Finch 225-379-
1572
Both District and State crews perform
deck patching, crack sealing, and
joint repairs. Contractors perform
railing and barrier repairs. General
maintenance manual includes
bridge maintenance items.
Currently revising manual to a
performance based specification.
Maine Brian
Pickard
207-287-
2661
State State crews perform deck patching,
cleaning, and joint repairs. They
do not specifically perform crack
sealing, but some sealing is
performed on bridge decks in
conjunction with road work.
Repair work is conducted based on
field crew experience; the agency is
currently in the process of creating
a manual.
9
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES (Continued)
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
Michigan Larry
Galehouse
517-322-
5774
Contractor Contractor performs cleaning,
sealing, deck patching, joint
repairs, and other bridge repairs
on bridge maintenance contracts
falling under “Scheduled” or
“Preventive” maintenance
categories. State crews perform
emergency repairs, such as high
load hits. There are specifications
for the repair work and at least
some of the work is under
warranty.
Mississippi John Vance 601-359-
7111
State State crews perform deck patching
and crack sealing. General
specifications cover materials and
methods, but they have no specific
maintenance manual.
Missouri Don Hillis 573-751-
2785
State State crews perform deck
patching, crack sealing, cleaning,
and smaller rehabilitation projects.
They have a maintenance manual
that covers repair work.
Nevada Frank Taylor 775-888-
7050
State State crews perform deck
patching, crack sealing, and
cleaning work. They have a
“Maintenance Management
Series” that covers repair work
materials and methods.
10
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES (Continued)
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
New Jersey Rod
Roberson
609-530-
2590
Both State crews typically perform
maintenance work. Contracts will
occasionally be put out for bid for
large quantities of repair work.
Maintenance work includes crack
sealing, joint repairs, deck
patching, and cleaning. They
have a set of operational bulletins
that directs how repair work is to
be performed.
New
Mexico
Earl Franks Both Reactive maintenance, such as
blown joints, is performed by
State crews. Deck patching and
surface sealing are performed by a
contractor under a general
services agreement. They do not
have a manual, but they do have
specifications that cover
contracted items.
North
Carolina
Steve
Varnedoe
919-715-
5662
State Field crews from the Field Bridge
Maintenance operations perform
any work, including small bridge
replacement.
Ohio Brad Fagrell 614-466-
3893
State Deck patching, crack sealing, and
cleaning are performed by District
crews, but usually as reactive
maintenance. They have a
maintenance manual that covers
repair work. They are in the
process of allocating more funds
for preventive maintenance and
may increase contract work.
11
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES (Continued)
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
Oklahoma John Fuller 405-521-
4675
State Deck patching, crack sealing, and
railing repairs are conducted by
State crews. Work is usually
based upon the experience of the
crew, but they do have general
specifications.
Oregon Doug
Tindall
503-986-
3005
Both Repairs, such as cleaning, deck
patching, crack sealing, and joint
repairs, are conducted by State
crews. Large quantities of repair
work may be performed by
contractors or by State crews with
no specific reasoning for one way
or the other. State crew repairs
generally performed based on
experience and general
specifications cover contract
work.
South
Carolina
Leaf Woods 803-737-
1290
Both Majority of maintenance work is
performed by State crews,
including deck patching, crack
sealing, joint repair, and some
HMA overlay work. Large
quantities of deck patching or
joint repairs may be performed by
contractors. Most repair work is
based on crew experience.
Tennessee Gerald
Gregory
615-741-
2027
State County and District crews
perform cleaning activities. State
crews perform deck patching and
joint repairs. Repair work is
performed based upon experience;
specifications cover materials but
not methods.
12
APPENDIX A - SUMMARY OF STATE HIGHWAY AGENCIES’ BRIDGE DECK
MAINTENANCE PRACTICES (Continued)
State
Contact
Name
Phone
Number
Maintenance
work
performed by
State or
Contractor? Comments
Washington Ken
Kirkland
360-705-
7851
State State crews perform joint repairs,
deck patching, and crack sealing.
Maintenance work is covered
under the construction and design
manual.
Wisconsin Finn
Hubbard
608-266-
8489
State County crews perform deck
patching, cleaning, crack sealing,
and deck sealing. Specifications
provide approved materials but
repair work is based upon crew
experience.
13
APPENDIX B
PROPOSED SPECIFICATION FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING
AND EPOXY-RESIN BASE ADHESIVE INJECTION
14
15
APPENDIX B
PROPOSED SPECIFICATION FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING
AND EPOXY-RESIN BASE ADHESIVE INJECTION
X02.01 DESCRIPTION. This work consists of repairing minor spalling and cracking in
prestressed concrete I-beams. The work under this item shall include all material,
equipment, and labor for repairing spalls and cracks in prestressed concrete I-beams.
This work includes, but is not necessarily limited to, removal and disposal of damaged or
deteriorated concrete; cleaning and preparing of the bonding surface; cleaning of the
existing reinforcement steel; furnishing and injecting epoxy-resin base adhesives;
constructing falsework to support forms, where required; constructing forms; and placing
new concrete. Spall and crack repair work shall be performed at locations indicated on
the Plans or as directed by the Engineer and shall conform to the requirements of the
Standard Specifications and these Special Provisions.
The purposes of this work are to restore continuity to the I-beam, protect the steel
reinforcement, and restore the shape of the I-beam. This work does not include repair or
replacement of damaged prestressing tendons. If damaged prestressing steel is
encountered during repair work, work shall be suspended and the Engineer notified.
X02.02 MATERIALS. All products indicated below must be listed in the ADOT
Approved Products List.
X02.02.1 Patching Material. Patching material shall be a polymer-modified portland
cement concrete with a minimum ultimate strength, f'c = 5,500 psi at 28 days and shall
attain a minimum strength of 3,500 psi within 6 to 8 hours before forming can be
stripped. The material specification shall meet or exceed the requirements delineated in
the Standard Specifications.
X02.02.2 Epoxy Injection Material. Injection material shall be a low viscosity, two-part
epoxy-resin system conforming to the requirements of ASTM C-881, Type IV, and
shall meet or exceed the requirements delineated in the Standard Specifications. The
material shall also be the required grade and class to satisfactorily perform its function.
a. Injection Equipment. The equipment used to meter and mix the two
injection adhesive components and inject the mixed adhesive shall be portable,
positive displacement type pumps with interlock to provide positive ratio control
of exact proportions of the two components at the nozzle.
The injection equipment shall have the automatic pressure control capable of
discharging the mixed adhesive at any preset pressure up to 160 + 5 psi.
16
The equipment shall have the capability of maintaining the volume ratio for the
injection of the adhesive prescribed by the manufacturer of the adhesive within
the tolerance of +5 percent by volume at any discharge pressure up to 160 psi.
The injection equipment shall be equipped with sensors on both the component A
and component B reservoirs that will automatically stop the machine when only
one component is being pumped to the mixer head.
d. Surface Seal. A surface seal material as recommended by the adhesive
manufacturer shall be used to confine the injection adhesive in the crack during
injection and curing. It shall have adequate strength to hold injection fittings or
ports and prevent vent leakage during injection.
X02.03 CONSTRUCTION METHODS. The Contractor shall inspect the structure in
order to become acquainted with the nature and extent of the work. Construction
methods shall conform with the Standard Specifications. Where this specification
deviates from the Standard Specification, the intent of this text shall govern.
X02.03.1 Spall Repair.
a. Surface Preparation. All deteriorated, disintegrated, soft, fractured, or
otherwise defective concrete shall be removed from the areas to be repaired to a
depth sufficient to expose a bonding surface of sound material as determined by
the Engineer. Impact tools may be used only with the approval of the Engineer.
At the direction of the Engineer, the perimeter of the area to be repaired will be
saw cut to a depth of 0.5 inches. Thin or feathered edges will not be permitted.
Once all deteriorated concrete has been removed, the existing sound concrete
shall be maintained in a clean, rough, and surface-saturated moist condition until
the concrete repair has been completed. When an epoxy-resin agent is specified,
the prepared sound concrete surface shall be thoroughly dried prior to application
of the epoxy-resin. Care shall be taken during the removal of the designated
portions of the structure to avoid damaging the portions that are to remain in
place. Any damage caused by the Contractor to the existing structure that is
designated to remain in place shall be repaired or replaced by the Contractor at the
Contractor’s expense to the satisfaction of the Engineer.
b. Reinforcing Steel. Care shall be exercised during concrete removal and
sawcutting to prevent damage to the reinforcing steel and prestressed tendons.
All corroded reinforcing bars shall be thoroughly cleaned to remove all rust. The
condition of the reinforcing steel and prestressing tendons will be inspected by the
Engineer before application of the concrete repair. Repair work shall be
suspended if damage to the prestressing tendons is encountered. Such damage
may affect the structural stability of an entire span and thus the measures needed
to correct the defect are numerous and varied, requiring structural or other
technical advice, and are beyond the scope of this work. Any damage to the
17
existing reinforcing steel caused by the Contractor shall be repaired or replaced at
the discretion of the Engineer at no additional cost to the Department.
c. Forms. Forms shall be used for repairs whenever necessary to confine the
concrete and shape it to the required lines. Such forms may partially require
progressive installation as the concrete is placed as a result of confinements for
placing concrete due to the location of the particular repair or restoration required.
The forms shall have sufficient strength to withstand the pressure resulting from
placing operations, shall be maintained rigidly in position, and shall be
sufficiently tight to prevent loss of mortar from the concrete. The use of form oils
is expressly forbidden; the Contractor shall use an alternate method or material for
facilitating form release that will not cause discoloration or staining of the
concrete. All such methods or materials are subject to the approval of the
Engineer.
d. Application.
1) Bonding Agent. Epoxy bonding agent shall be an all-purpose high-strength,
moisture-insensitive, two-part rigid epoxy adhesive conforming
to the requirements of ASTM C-881, Type V, and it shall meet the
approval of the Engineer, including contact time, fluidity, and application
temperature. The bonding agent shall also be one of those listed on the
ADOT Approved Products List.
The Contractor shall follow the manufacturer's recommendations for
curing the epoxy bonding agent prior to placing the patching mortar. The
patching mortar shall not be placed if the epoxy bonding agent has
exceeded the manufacturer's recommended contact time. If the epoxy
bonding agent has exceeded its contact time, the Contractor shall follow
the manufacturer's recommendations for re-application. An epoxy
bonding agent with an extended contact time should be used if required by
the timing of concrete placement and/or weather conditions.
2) Placing and Consolidation. Polymer-modified portland cement
concrete shall be placed, consolidated, and finished on a previously
prepared surface as described in this Specification, and to which an epoxy
bonding agent has been applied.
Patching materials shall not be applied when the ambient temperature is
below 40 degrees F or is not in accordance with the manufacturer’s
recommendations.
3) Finish. All exposed surfaces shall be finished straight and true,
approximating the original contour as close as practicable. The final
finished surfaces shall match the texture, color, and aggregate exposure of
18
the existing concrete surfaces adjoining or proximate to the area where
new concrete has been placed.
4) Curing. Curing procedures and methods shall comply with the
polymer-modified portland cement concrete manufacturer’s
recommendations and as set forth in the Standard Specifications, or as
otherwise directed by the Engineer. Use of curing compounds is not
permitted unless specifically required by the manufacturer.
X02.03.2 Epoxy Injection
a. Component Ratio Calibration Test. Before work is begun, the equipment
shall be ratio and pressure checked. These checks may be done in the field or in
the Contractor's office before the equipment is brought to the field. If equipment
is tested in the Contractor's office, a letter documenting the test results shall be
supplied to the Engineer.
b. Surface Preparation. All deteriorated concrete adjacent to the cracks and
areas of application shall be removed prior to proceeding with crack repairs.
Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt,
dust, grease, oil, efflorescence, or other foreign material matter detrimental to the
bond of the epoxy injection/surface seal system. Use of acids or other corrosives
will not be permitted. Cleaning methods shall not introduce foreign materials into
the crack repair area in such a manner that the penetration of the epoxy adhesive
is hindered.
Entry ports shall be provided along the crack at intervals recommended by the
manufacturer.
Surface seal material shall be applied to the face of the crack between and around
the entry ports. For through-cracks, the surface seal shall be applied to both faces.
The surface seal material shall have sufficient strength to withstand injection
pressures of 250 psi. The surface seal material shall have sufficient time to reach
adequate strength before the Contractor proceeds with the injection.
c. Epoxy Injection. Epoxy injection shall be performed in accordance with the
manufacturer’s recommended methods. If a recommended application procedure
is not available, the Contractor shall use the following epoxy injection technique:
1) Injection of epoxy adhesive shall begin at a lower entry port and
continue at sufficient pressure and for adequate duration to fill completely
all voids in excess of 0.002 inches to a depth of 12 inches.
2) Before epoxy injection is transferred to the next adjacent port where
epoxy adhesive has appeared, the resin exiting an adjacent port shall be
clear and free from impurities.
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3) This epoxy adhesive injection procedure shall continue until all cracks
within the crack network between the designated port interval are
completely filled.
4) If port-to-port travel of the epoxy adhesive is not indicated, the work
shall immediately be stopped and the Engineer notified.
5) Minimum ambient temperature at time of injection shall be 40 degrees
F, or as recommended by the manufacturer.
6) The applicator engaged in the epoxy injection process shall be familiar
with the specific epoxy injection method indicated, as well as the
operation, maintenance, and trouble-shooting of equipment.
d. Finishing. When cracks are completely filled, epoxy shall be cured for
sufficient time in accordance with the manufacturer’s recommendations. Surface
seal material and injection adhesive runs or spills shall be removed from concrete
surfaces in a manner recommended by the manufacturer and approved by the
Engineer. The face of the crack shall be finished flush to the adjacent surface and
show no indentations or protrusions caused by the placement of entry ports.
X02.03.3 Cleanup. The Contractor shall clean the worksite sufficiently prior to
opening the roadway to traffic. Cleanup shall include, but is not limited to, removing all
dirt and debris from the roadway and cleaning the repaired surface of loose concrete or
foreign matter.
X02.04 METHOD OF MEASUREMENT.
X02.04.1 "Spall Repair" will be measured by the square foot of spall area actually
repaired in accordance with the Plans and/or directed by the Engineer. For a spall at the
edge of the beam, the measurement will be made from one side only (side or bottom) of
the spall repair, whichever produces the larger area.
X02.04.2 “Epoxy Injection Crack Repair” will be measured by the lineal foot along the
centerline of the crack actually repaired in accordance with the Plans and/or as directed
by the Engineer. Through-cracks will be measured on one side of the beam only.
X02.05 BASIS OF PAYMENT. The accepted quantity of "Spall Repair" shall be paid
for at the contract unit price per square foot as listed in the Contract; “Epoxy Injection
Crack Repair” will be paid for at the contract unit price per linear foot as listed in the
Contract. The price so-stated shall be full compensation for the work, complete in place,
as described and specified herein, and accepted by the Engineer, including, but not
limited to, all labor, tools, materials, equipment (including scaffolds), and all other
incidentals required to finish the work.
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21
APPENDIX C
PROPOSED CHECKLIST FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING
AND EPOXY-RESIN BASE ADHESIVE INJECTION
22
23
APPENDIX C
PROPOSED CHECKLIST FOR PRESTRESSED
CONCRETE I-BEAM: MINOR REPAIR BY PATCHING
AND EPOXY-RESIN BASE ADHESIVE INJECTION
PRE-CONSTRUCTION
  Review Plans, Specifications, and Special Provisions for special information,
completeness, and accuracy
  Prepare yourself and your staff for night work, if necessary
  Kick-off meeting with designer (Pre-Job Meeting)
• Clarify location of beams to be repaired
• Clarify plans and specifications
• Discuss lessons learned from past experiences
  Material testing
• Review Standard Specifications
• Review Special Provisions
• Prepare to sample and test cylinders
• Ensure that testing staff is certified to perform the required testing
• Review contractor’s quality control plan, if specified
• Mix Design
• Epoxy injection equipment calibration test
  Create list of Submittals
  Review Contingency Plans
• What to do when things go wrong
• Plant or equipment breakdown
• Modulus of rupture does not meet requirements for opening to traffic
DETERMINE EXACT LIMITS OF CONCRETE REMOVAL
  Review locations to be removed to ensure that all unsound material is removed
  Prepare a beam repair log
• Show location and dimension of spall and crack repairs
• Before pre-sawing begins, match the quantities of spall and crack repairs on the
plans with the estimate from the field review
CONCRETE REMOVAL AND CRACK PREPARATION
  Concrete removal should be performed without damage to concrete that is to remain
in place
  Any damage to portions of the structure that are to remain in place should be repaired
to a condition satisfactory to the engineer
  Repair perimeters can be pre-sawed prior to the removal and replacement
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  Inspect for sound bonding surface and require additional removal if unsound material
is still present
  Inspect reinforcement for damage; damaged prestressing tendons may require more
extensive repair work
  Inspect concrete adjacent to cracks to identify any deteriorated concrete
  Crack surfaces clean of debris, oils, and so on
CONCRETE PLACEMENT
  Ensure that repair preparation has been inspected and the contractor is permitted to
place concrete
  Verify that the bonding agent is applied to the entire bonding surface and has not
dried
  Check that epoxy injection ports are spaced as recommended by the manufacturer
CONCRETE ARRIVES ON-SITE
  Check temperature
  Watch for consistency of concrete
• How long is the material workable?
• How much slump does it have?
• Other properties
CONCRETE TESTING
  Concrete testing requirements are contract-specific
  Make arrangements with testing personnel to get the test results to the Inspector, who
will reopen the bridge
EPOXY INJECTION
  Epoxy exiting adjacent port is free of impurities
CLEAN-UP AND OPENING TO TRAFFIC
  Recommend a street sweeper
  Concrete quantity should be agreed upon between the State and the contractor
  Quantity is based on actual measurements, not quantity on concrete tickets
APPLICABLE STANDARDS AND STANDARD SPECIFICATIONS
  Division I: General Provisions
  Section 601: Concrete Structures
25
  Section 602: Prestressing Concrete
  Section 1006: Portland Cement Concrete
  Section 1015: Epoxy Materials
26
27
APPENDIX D
PROPOSED SPECIFICATION FOR BRIDGE
DECK REPAIR: FULL-DEPTH PATCH
28
29
APPENDIX D
PROPOSED SPECIFICATION FOR BRIDGE
DECK REPAIR: FULL-DEPTH PATCH
X03.01 DESCRIPTION. This work consists of deck slab repairs requiring removal and
replacement to the full depth of the deck. The work under this item shall include all
material, equipment, and labor for full-depth patching of the bridge deck. This work
includes, but is not necessarily limited to, bituminous surface removal and replacement, if
required; removal and disposal of deteriorated concrete; constructing falsework to
support forms; constructing forms; cleaning and repairing of the existing reinforcement
steel, where required; cleaning and preparing of the bonding surface; and placing new
concrete. Full-depth deck repairs shall be performed at locations indicated on the Plans
or as directed by the Engineer, and shall conform to the requirements of the Standard
Specifications and these Special Provisions.
X03.02 MATERIALS. All products indicated below must be listed in the ADOT
Approved Products List.
Patch materials shall attain compressive strength of 2,000 psi within 6 hours. The patch
material shall attain the required compressive strength of 4,000 psi prior to opening to
traffic.
X03.02.1 Accelerated Strength Portland Cement Concrete Patch Material.
Accelerated strength patching material shall be a mixture consisting of Type III portland
cement and calcium chloride or other accelerators meeting AASHTO M 144 and shall
attain a compressive strength of at least 2,000 psi in 6 hours. The material specification
shall conform to the requirements of the Standard Specifications Section 1006 for Class S
concrete.
X03.02.2 Rapid Setting Patch Material. Rapid setting patch material shall be
approved by the Engineer and shall be listed in the ADOT Approved Products List.
X03.02.3 Reinforcement Steel. Materials furnished for reinforcement steel shall
conform to the requirements of the Standard Specifications Section 1003.
X03.03 EQUIPMENT. The equipment used shall be subject to the approval of the
Engineer and shall meet the following requirements:
X03.03.1 Surface Preparation Equipment. Surface preparation and concrete
removal equipment shall be according to the applicable portions of Sections 202 and 601
of the Standard Specifications and the following:
a. Sawing Equipment. Sawing equipment shall be a concrete saw capable of
sawing concrete and embedded reinforcing steel to the specified depth.
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b. Blast Cleaning Equipment. The blast cleaning may be performed by wet
sandblasting, high-pressure waterblasting, shotblasting, or abrasive blasting.
Blast cleaning equipment shall be capable of removing rust and old concrete from
exposed reinforcement bars, and shall have oil traps.
c. Power-Driven Hand Tools. Power-driven hand tools will be permitted,
including light-weight jackhammers. Chipping hammers heavier than a nominal
15-lb class shall not be used for final removal at the boundary of full-depth
repairs. Jackhammers or chipping hammers shall not be operated at an angle in
excess of 45 degrees measured from the surface of the deck.
d. Hydro-Scarification Equipment. The hydro-scarification equipment shall
consist of filtering and pumping units operating with a remote-controlled robotic
device. The equipment may use river, stream, or lake water. Operation of the
equipment shall be performed and supervised by qualified personnel certified by
the equipment manufacturer. Evidence of certification shall be presented to the
Engineer. The equipment shall be capable of removing concrete to the specified
depth and removing rust and concrete particles from exposed reinforcing bars.
Hydroscarification equipment shall be calibrated before being used and shall
operate at a minimum of 18,000 psi.
X03.03.2 Concrete Mixing Equipment. Equipment for proportioning and mixing
the concrete shall be according to the Standard Specifications Section 1006.
X03.03.3 Finishing Equipment. Finishing equipment shall be according to the
Standard Specifications Section 601. Adequate hand tools will be permitted for placing
and consolidating concrete in the patch areas and for finishing small patches.
X03.04 CONSTRUCTION REQUIREMENTS. Sidewalks, curbs, drains, and
reinforcement and/or existing transverse and longitudinal joints, which are to remain in
place, shall be protected from damage during removal and cleaning operations. All
damage caused by the Contractor shall be corrected, at the Contractor’s expense, to the
satisfaction of the Engineer.
The Contractor shall control the runoff water generated by the various construction
activities in such a manner as to reduce, to the maximum extent practicable, the discharge
of construction debris into adjacent waters, and shall properly dispose of the solids
generated according to the Standard Specifications. Runoff water will not be allowed to
constitute a hazard on adjacent or underlying roadways, waterways, drainage areas, or
railroads, nor be allowed to erode existing slopes.
X03.04.1 Bituminous Surface Removal. In special cases where bituminous
concrete overlays are part of the existing deck surface, the bituminous concrete surface
course and all waterproofing membrane shall be removed and disposed of according to
applicable portions of the Standard Specifications Section 202, except milling equipment
31
will not be allowed if the deck is to receive a waterproofing membrane system. Removal
of the bituminous surface by the use of radiant or direct heat will not be permitted.
The Contractor shall insure that the process of removal of the bituminous overlay and the
waterproofing membrane will not cause any damage to the underlying concrete deck
and/or bridge joints to remain. The Contractor shall also insure that the proposed removal
method will completely remove the existing waterproofing membrane to allow for the
proposed deck patching repairs and new waterproofing system installation, if required.
The Contractor will note that the thickness of the existing pavement may vary. The
specifications, including gross weight(s) of the proposed equipment and/or machinery to
be used for the removal operation, shall be submitted to the Engineer for approval prior to
the start of work. The proposed equipment and/or machinery loads shall not exceed
40,000 pounds or the posted load limit for the bridge, whichever is less. Damage caused
to the deck and/or bridge joints as a result of the Contractor’s operation shall be repaired
to the satisfaction of the Engineer at no additional cost to the State.
The bituminous overlay and waterproofing removal shall be performed in accordance
with the sequence of construction and traffic controls indicated on the Plans. Where
required, the Contractor will saw cut the pavement to prevent over-breakage into the
vehicular travel areas. In the event that this type of over-breakage does occur, the
Contractor shall immediately patch the damaged bituminous areas using a bituminous
patching material which conforms with the Standard Specifications, at no additional cost
to the State.
The removal operation shall not endanger the general public or interfere with the
established traffic maintenance plan. All materials removed must be transported from the
site and legally disposed of by the Contractor.
X03.04.2 Surface Preparation. All loose, disintegrated, and unsound concrete shall
be removed from portions of the deck slab shown on the plans or as designated by the
Engineer. The Engineer will determine the limits of removal as the work progresses.
The Contractor shall take care not to damage reinforcement bars or expansion joints
which are to remain in place. Any damage to reinforcement bars or expansion joints shall
be corrected at the Contractor's expense. All loose reinforcement bars, as determined by
the Engineer, shall be retied at the Contractor's expense.
Full-depth removal shall be performed according to the Standard Specifications Section
202. Saw cuts shall be made on the top of the deck, except those boundaries along the
face of curbs, parapets, and joints or where hydro-scarification provided sharp vertical
edges. The top saw cut may be omitted if replacement of an existing bituminous overlay
is required.
Forms and any required falsework for full-depth repair shall be in accordance with the
Standard Specifications.
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All form work shall be removed after the curing sequence is complete and prior to
opening to traffic.
X03.04.3 Reinforcement. Care shall be exercised during concrete removal to protect
the in-place reinforcement bars and structural steel from damage. Any damage to the
reinforcement bars or structural steel to remain in place shall be repaired or replaced to
the satisfaction of the Engineer at the Contractor's expense. No payment will be allowed
for removal and replacement of reinforcement bars damaged by the Contractor in the
performance of their work or for any increases in repair dimensions needed to provide
splices for these replacement bars or repair to structural steel.
All existing reinforcement bars shall remain in place except as herein provided for
corroded bars. Tying of loose bars will be required. Reinforcing bars which have been
cut or have lost 25 percent or more of their original cross sectional area shall be
supplemented by new in kind reinforcement bars. New bars shall be lapped a minimum
of 32 bar diameters to existing bars. An approved “squeeze type” mechanical bar splice
capable of developing in tension at least 125 percent of the yield strength of the existing
bar shall be used when it is not feasible to provide the minimum bar lap. No welding of
bars will be permitted.
X03.04.4 Cleaning. Immediately after completion of the concrete removal and
reinforcement repairs, the repair areas shall be cleaned of dust and debris. Once the
initial cleaning is completed, the repair areas shall be thoroughly blast cleaned to a
roughened appearance free from all foreign matter. Particular attention shall be given to
removal of concrete fines. Any method of cleaning which does not consistently produce
satisfactory results shall be discontinued and replaced by an acceptable method. All
debris, including water, resulting from the blast cleaning shall be confined and shall be
immediately and thoroughly removed from all areas of accumulation. If concrete
placement does not follow immediately after the final cleaning, the area shall be carefully
protected with well-anchored polyethylene sheeting.
Exposed reinforcement bars shall be free of dirt, detrimental scale, paint, oil, or other
foreign substances which may reduce bond with the concrete. A tight, non-scaling
coating of rust is not considered objectionable. Loose, scaling rust shall be removed by
rubbing with burlap, wire brushing, blast cleaning, or other methods approved by the
Engineer.
X03.04.5 Placement and Finishing of Concrete.
a. Grout. After the repair areas have been cleaned and immediately prior to
concrete placement, a bonding grout shall be applied to the prepared surface in
accordance with the manufacturer of the patch material and shall be approved by
the Engineer.
b. Concrete Placement. The concrete shall be placed, consolidated, and
finished in accordance with Section 601 of the Standard Specifications and as
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herein specified. The concrete repair shall be finished to the cross section of the
bridge deck. The patch surface shall be struck off flush with the original deck
surface.
When an overlay system is not specified, the patches shall be finished in
accordance with Section 601 of the Standard Specifications, followed by a light
brooming.
c. Curing and Protection. Concrete patches shall be cured according to the
Standard Specifications Section 1006, and the curing period shall be 72 hours. A
72-hour minimum drying period shall be required before placing waterproofing or
bituminous surfacing, if required.
X03.04.6 Bituminous Surface Repair. If required, replacing waterproofing
membrane and bituminous surfacing shall be performed in accordance with appropriate
portions of Sections 407 or 411 of the Standard Specifications depending upon the
material of the existing bituminous surface. The Engineer will determine the required
replacement material.
X03.04.7 Opening to Traffic. The Contractor shall clean the worksite sufficiently
prior to opening the roadway to traffic. Cleanup shall include, but is not limited to,
removing all dirt and debris from the roadway and cleaning the repaired surface of loose
concrete or foreign matter.
No traffic will be permitted on a patch until after the specified cure period, and the
concrete has obtained a minimum compressive strength of 4,000 psi.
Construction equipment will be permitted on a patch during the cure period if the
concrete has obtained the minimum required strength.
X03.05 METHOD OF MEASUREMENT.
X03.05.1 “Deck Slab Repair – Full Depth” will be measured by the square yard of deck
area actually removed and repaired in accordance with the Plans and/or directed by the
Engineer.
X03.05.2 When specified, “Bituminous Surface Removal” will be measured by the
square yard of surface area actually removed in accordance with the Plans and/or directed
by the Engineer.
X03.05.3 When specified, “Bituminous Surface Repair” will be measured by the ton for
the mixture actually used in accordance with the Plans and/or directed by the Engineer.
X03.06 BASIS OF PAYMENT. The accepted quantity of "Deck Slab Repair – Full
Depth" shall be paid for at the contract unit price per square yard as listed in the Contract;
if required, “Bituminous Surface Removal” will be paid for at the contract unit price per
34
square yard and “Bituminous Surface Repair” will be paid for at the contract unit price
per ton as listed in the Contract. The price so-stated shall be full compensation for the
work, complete in place, as described and specified herein, and accepted by the Engineer,
including, but not limited to, all labor, tools, materials, equipment (including false work),
and all other incidentals required to finish the work.
When corroded reinforcement bars are encountered in the performance of this work and
replacement is required, the Contractor will be paid according to the Standard
Specifications Section 109.
35
REFERENCES
Arizona Department of Transportation. 2000. Standard Specifications for Road and
Bridge Construction. Arizona Department of Transportation, Phoenix, AZ.
Arizona Department of Transportation. 2003. Contractor Services Statewide Bridge
Repair – Draft. Arizona Department of Transportation, Phoenix, AZ.
California Department of Transportation. 2001. Construction Manual. California
Department of Transporation, Sacramento, CA.
California Department of Transportation. 2001. Remove Asphalt Concrete Surfacing.
Standard Special Specifications 15-875(15REMA)_R08-20-01. California Department of
Transporation, Sacramento, CA.
California Department of Transportation. 2001. Remove Concrete Deck Surface.
Standard Special Specifications 15-885(15REMC)_R08-20-01. California Department of
Transporation, Sacramento, CA.
California Department of Transportation. 2000. Remove Unsound Concrete. Standard
Special Specifications 15-940_B10-05-00. California Department of Transporation,
Sacramento, CA.
California Department of Transportation. 1999. Bonding Portland Cement Concrete
Patches. Standard Special Specifications 51-810_B07-30-99. California Department of
Transporation, Sacramento, CA.
California Department of Transportation. 1999. Portland Cement Concrete Patches.
Standard Special Specifications 51-820_B07-30-99. California Department of
Transporation, Sacramento, CA.
California Department of Transportation. 1999. Rapid Setting Concrete Patches.
Standard Special Specifications 51-830_B07-30-99. California Department of
Transporation, Sacramento, CA.
California Department of Transportation. 1998. Maintenance Manual. California
Department of Transporation, Sacramento, CA.
Connecticut Department of Transportation. 2000. Bridge Deck Concrete (Revision of
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Department of Transportation, Newington, CT.
Connecticut Department of Transportation. 1997. Manual of Organization, Functions
and Procedures. Connecticut Department of Transportation, Newington, CT.
36
Illinois Department of Transportation. 2004. Construction Inspector’s Checklist for
Bridge Superstructures. Construction Manual Addendum 04-2004. Illinois Department
of Transportation, Peoria, IL.
Illinois Department of Transportation. 2004. Construction Inspector’s Checklist for
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2004. Illinois Department of Transportation, Peoria, IL.
Illinois Department of Transportation. 2004. Construction Inspector’s Checklist for
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Peoria, IL.
Illinois Department of Transportation. 2003. Deck Slab Repair. Guide Bridge Special
Provisions No. 28. Illinois Department of Transportation, Peoria, IL.
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Michigan Department of Transportation. 2004. Bridge Capital Scheduled Maintenance
Manual. Michigan Department of Transportation, Lansing, MI.
Michigan Department of Transportation. 2003. Standard Specifications for
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Michigan Department of Transportation. 2001. Structure Repair with Latex Modified
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Lansing, MI.
Missouri Department of Transportation. 2002. Standard Specifications for Highway
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Pennsylvania Department of Transportation. 2004. Maintenance Manual. Publication
23. Pennsylvania Department of Transportation, Harrisburg, PA.