2002 Interim Edition non aUCy Perera terol Ceca) ee Transportation Officials nea atAASHTO LRFD Bridge Construction Specifications 2002 Interim Edition Published by the American Association of State Highway and Transportation Officials Game 444 North Capitol Street, N.W., Suite 249 i ») Washington, DC 20001 a www.transportation.org Sie Copyright © 2002 by the American Association of State Highway and Transportation Officials. All Rights Reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without written permission of the publishers. ISBN: 1-56051-178-8‘To recipients of the AASHTO LRFD Bridge Construction Specifications, First Edition (1998): Instructions Interim revisions have been made to the AASHTO LRED Bridge Construction Specifications, First Edition (1998). This packet contains the revised pages. They have been desigried to replace the corresponding pages in the book and are numbered accordingly. One vertical line in the margins indicates revisions were approved in 1999 by the AASHTO ‘Subcommittee on Bridges and Structures. Two vertical lines in the margins indicates revisions were approved in 2000 by the AASHTO Subcommittee on Bridges and Structures, Three vertical lines in the margins indicates revisions were approved in 2001 by the AASHTO Subcommittee on Bridges and Structures. Four vertical line in the margins indicates revisions were approved in 2002 by the AASHTO Subcommittee on Bridges and Structures. To keep your Specifications correct and up-to-date, please replace the appropriate pages in the book with the pages in this packet.AASHTO LRFD Bridge Construction Specifications 2001 Interim Edition Published by the American Association of Same State Highway and Transportation Officials cf ) 444 North Capitol Street, N.W., Suite 249 a Washington, DC 20001 en Copyright © 2001 by the American Association of State Highway and Transportation Officials. All Rights Reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without written permission of the publishers. ISBN: 1-56051-157-5‘To recipients of the AASHTO LRFD Bridge Construction Specifications, First Edition (1998) Instructions Interim revisions have been made to the AASHTO LRFD Bridge Construction Specifications, First Edition (1998). This packet contains the revised pages. They have been designed to replace the cor- responding pages in the book and are numbered accordingly. ‘One vertical line in the margins indicates revisions were approved in 1999 by the AASHTO Sub- committee on Bridges and Structures. Two vertical lines in the margins indicates the revisions were approved in 2000 by the AASHTO Subcommittee on Bridges and Structures. Three vertical lines in the margins indicates the revisions were approved in 2001 by the AASHTO Subcommittee on Bridges and Structures. ‘To keep your Specifications correct and up-to-date, please replace the appropriate pages in the book with the pages in this packet.AASHTO LRFD Bridge Construction Specifications 2000 Interim Edition Published by the American Association of State Highway and Transportation Officials 444 North Capitol Street, N.W., Suite 249 Washington, DC 20001 Copyright © 2000 by the American Association of State Highway and ‘Transportation Officials. All Rights Reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without written permission of the publishers. ISBN: 1-86051-145-1To recipients of the AASHTO LRFD Bridge Construction Specifications, First Edition (1998) Instructions Interim revisions have been made to the AASHTO LRFD Bridge Construction Specifications, First Edition (1998). This packet contains the revised pages. They have been designed to replace the cor- responding pages in the book and are numbered accordingly. One vertical line in the margins indicates revisions were approved in 1999 by the AASHTO Sub- committee on Bridges and Structures. Two vertical lines in the margins indicate the revisions were approved in 2000 by the AASHTO Subcommittee on Bridges and Structures. ‘To keep your Specifications correct and up-to-date, please replace the appropriate pages in the book with the pages in this packet.AASHTO LRFD Bridge Construction Specifications 1999 Interim E Published by the American Association of Gam, State Highway and Transportation Officials \ 444 North Capitol Street, N.W., Suite 249 Washington, D.C. 20001 ar Copyright © 2000 by the American Association of State Highway and Transportation Officials. All Rights Reserved. Printed in the United States ‘of America. This book, or parts thereof, may not be reproduced in any form with out written permission of the publishers. ISBN: 1-66051-130-3To recipients of the AASHTO LRFD Bridge Construction Specifications, First Edition (1998) Instructions Interim revisions have been made to the AASHTO LRFD Bridge Specifications, First Edition (1998). This packet contains the revised pages. They have been designed to replace the corresponding pages in the book and are numbered accordingly. One vertical line in the margins indicates revisions were approved in 1999 by the AASHTO Sub- committee on Bridges and Structures. To keep your Specifications correct and up-to-date, please replace the appropriate pages in the book with the pages in this packet.AASHTO LRFD Bridge Construction Specifications First Edition 1998 Published by the American Association of State Highway and Transportation Officials 444 North Capitol Street, N.W., Suite 249 Washington, D.C. 20001 Copyright © 1998 by the American Association of State Highway and Transportation Officials. All Rights Reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without written permission of the publishers. ISBN: 1-86051-047-1AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS EXECUTIVE COMMITTEE 1996-1997 Officers President: Darrel Rensink, lowa Vice President: David Winstead, Maryland Secretary/ Treasurer: Clyde E. Pyer, Maryland Regional Representatives RegionI Carlos I. Pesquera, Puerto Rico Region II Robert L. Robinson, Mississippi Region Il Robert A. Welke, Michigan Region IV Marshall W. Moore, North Dakota Non-Voting Members Immediate Past President: Wm, G. Burnett, P.E., Texas Executive Director: Francis B. Francois, Washington, D.C.HIGHWAY SUBCOMMITTEE ON BRIDGES AND STRUCTURES 1998 Chairman: David Pope, Wyoming, Vice Chairman: James E. Roberts, California Secretary: David Densmore, Federal Highway Administration ALABAMA, William F, Conway ALASKA, Steve Bradford, Ray Shumway ARIZONA, William R. Brucsch, F. Daniel Davis ARKANSAS, Dale Loe CALIFORNIA, James E. Roberts COLORADO, Stephen Horton CONNECTICUT, Gordon Barton DELAWARE, Chao H. Hu D.C., Donald Cooney FLORIDA, Jerry Potter GEORGIA, Paul Liles HAWAII, Donald C. Orellas IDAHO, Matthew M. Farrar ILLINOIS, Ralph E. Anderson INDIANA, Mary Jo Hamman IOWA, William A. Lundquist KANSAS, Kenneth F. Hurst KENTUCKY, Stephen E. Goodpaster LOUISIANA, Norval Knapp, Wayne Aymond MAINE, James E. Tukey MARYLAND, Earle S. Freedman MASSACHUSETTS, Alexander K. Bardow MICHIGAN, Sudhakar Kulkarni ‘MINNESOTA, Donald J. Flemming MISSISSIPPI, Wilbur F. Massey MISSOURI, Allen F. Laffoon MONTANA, William S. Fullerton NEBRASKA, Lyman D. Freemon NEVADA, William C. Crawford, Jr. NEW HAMPSHIRE, James A. Moore NEW JERSEY, Harry A. Casper, Jr. NEW MEXICO, Jimmy D. Camp NEW YORK, James O'Connell NORTH CAROLINA, William J. Rogers NORTH DAKOTA, Steven J. Miller OHIO, Brad W. Fagrell OKLAHOMA, Robert J. Rusch OREGON, Terry J. Shike PENNSYLVANIA, Scott Christie PUERTO RICO, Hector Camacho RHODE ISLAND, Kazem Farhoumand SOUTH CAROLINA, Randy R. Cannon SOUTH DAKOTA, John Cole ‘TENNESSEE, Ed Wasserman TEXAS, Richard Wilkison U.S. DOT, David Densmore, (FHWA), Nick E. Mpras, (usa) UTAH, P. K. Mohanty VERMONT, Warren B. Tripp VIRGINIA, Malcolm T. Kerley WASHINGTON, Myint Li WEST VIRGINIA, James Sothen WISCONSIN, Stanley W. Woods WYOMING, B. Patrick Collins ALBERTA, Dilip K. Dasmohapatra BRITISH COLUMBIA, Peter Brett MANITOBA, W. Saltzberg MARIANA ISLANDS, Elizabeth H. Salas-Balajadia NEW BRUNSWICK, G. A. Rushton NEWFOUNDLAND, Peter Lester NORTHWEST TERRITORIES, Jivko ivkov NOVA SCOTIA, Al MacRae ONTARIO, Ranjit S. Reel SASKATCHEWAN, Lome J. Hamblin MASS. METRO. DIST. COMM., David Leniardt N.J. TURNPIKE AUTHORITY, Wallace R. Grant PORT AUTHORITY OF N.Y. AND NJ., Joseph K. Kelly N.Y. STATE BRIDGE AUTHORITY, Williem Moreau BUREAU OF INDIAN AFFAIRS, Wade Cosey U.S, DEPARTMENT OF AGRICULTURE-FOREST SERVICE, Nelson Hernandez MILITARY TRAFFIC MANAGEMENT COMMAND, Robert D. Franz US. ARMY CORPS OF ENGINEERS-DEPARTMENT (OF THE ARMY, Paul C. T. TanPREFACE ‘The AASHTO LRFD Bridge Construction Specifications has the following 29 sections. Tables of Contents precede each section, 1. Structure Excavation and Backfill 2. Removal of Existing Structures 3. Temporary Works 4, Driven Foundation Piles 5. Drilled Piles and Shafts 6. Ground Anchors 7. Earth Retaining Systems 8. Conerete Structures 9. Reinforcing Steel 10. Prestressing I. Steel Structures 12, Steel Grid Flooring 13, Painting 14, Stone Masonry 15. Concrete Block and Brick Masonry 16, Timber Structures 17. Preservative Treatment of Wood 18. Bearing Devices 19, Bridge Deck Joint Seals 20. Railings 21, Waterproofing 22. Slope Protection 23. Miscellaneous Metal 24, Pneumatically Applied Mortar 25, Steel and Concrete Tunnel Liners 26. Metal Culverts 21. Concrete Culverts 28. Wearing Surfaces 29. Embedment AnchorsFOREWORD ‘The first broadly recognized national standard for the design and construction of bridges in the United States ‘was published in 1931 by the American Association of State Highway Officials (AASHO), the predecessor to AASHTO. With the advent of the automobile and the establishment of highway departments in all of the ‘American states dating back to just before the turn of the century, the design, construction and maintenance of ‘most U.S. bridges was the responsibility of these depart- ‘ments and, more specifically, the chief bridge engineer within each department. It was natural, therefore, that these engineers, acting collectively as the Subcommittee (on Bridges and Structures, would become the author and ‘guardian of this first bridge standard, ‘This first publication was entitled Standard Specifica- tions jor Highway Bridges and Incidencal Structures. It quickly became the de facto national standard and, as such, was adopted and used by not only the state high- way departments but also other bridge-owning authori- ties and agencies in the United States and abroad. Rather carly on, the last three words of the original title were dropped and it has been reissued in consecutive editions at approximately four year intervals ever since as Stan- dard Specifications for Highway Bridges, with the 16th Edition appearing in 1996, ‘The body of knowledge related to the design of high- way bridges has grown enormously since 1931 and con- tinues to do so. Theory and practice have evolved ‘greatly, reflecting advances through research in under- standing the properties of materials, in improved materi- als, in more rational and accurate analysis of structural behavior, in the advent of computers and rapidly advanc- ing computer technology, in the study of external events, representing particular hazards to bridges such as seismic events and stream scour, and in many other areas. The pace of advances in these areas has, if anything, stepped up in recent years. To accommodate this growth in bridge engineering knowledge, the Subcommittee on Bridges and Structures has been granted the authority under AASHTO’s governing documents to approve and issue Bridge Interims each year, not only with respect to Standard Specifications but also to incrementally modify and enhance the twenty-odd additional documents on bridges and structures engineering that are under its {guidance and sponsorship. In 1986, the Subcommittee submitted a request to the AASHTO Standing Committee on Research to undertake fan assessment of U.S. bridge design specifications, review foreign design specifications and codes, consider design philosophies alternative to those underlying Stan- dard Specifications, and to render recommendations based on these investigations. This work was accom- plished under the National Cooperative Highway Research Program, an applied research program directed by the AASHTO Standing Committee on Research and administered on behalf of AASHTO by the Transporta- tion Research Board. The work was completed in 1987, and, as might be expected with a standard incrementally adjusted over the years, the Standard Specifications were Judged to include discernible gaps, inconsistencies, and even some conflicts. Beyond this, the specification did not reflect or incorporate the most recently developing design philosophy, load and resistance factor design (LRFD), a philosophy which has been gaining ground in other areas of structural engineering and in other pats of the world such as Canada and Europe. From its inception until the early 1970s, the sole design philosophy embedded within Standard Specifica- tions was one known as working stress design (WSD). WSD establishes allowable stresses as a fraction or per- centage of a given material's load-carrying capacity, and requires that calculated design stresses not exceed those allowable stresses. Beginning in the early 1970s, WSD began to be adjusted to reflect the variable predictability of certain load types, such as vehicular loads and. wind forces, through adjusting design factors, a design philos- ‘phy referred to as load factor design (LFD). Both WSD and LFD ae reflected in the current edition of Standard Specifications. ‘A further philosophical extension results from consid- ering the variability in the properties of stuctural ele- ments, in similar fashion to load variabiltes. While considered to a limited extent in LFD, the design philos- ‘phy of load and resistance factor design (LRFD) takes variability in the behavior of structural elements into account in an explicit manner. LRFD relies on extensive use of slatistcal methods, but sets forth the results in a ‘manner readily usable by bridge designers ard analysts. ‘The principal recommendation of the assessment ‘completed in 1987, therefore, was the development of an entirely new LRED bridge design standard. A multi-year, exceptionally comprehensive NCHRP project to accom. plish this goal was. subsequently approved by the AASHTO Standing Committee on Research. Once underway, NCHRP Project 12-33 took five years to com- plete, and resulted in this document, the AASHTO LRED Bridge Design Specifications. Under the frequent review of the AASHTO Highway Subcommittee on Bridges and Structures and its twenty Technical Committees, the specifications were developed by a team of more thanfifty members, including some of the best bridge engi- neering talent in the U.S. and elsewhere, guided by a dis- tinguished project panel. The effort included the incorporation of state-of-the-art knowledge, and the cooperation and input of industry groups. It has passed through five successive drafts, painstaking reviews, and ithas been systematically tested in trial designs in bridge design division of fourteen AASHTO member depart- ‘ments, as well as informally tested in many others. It rep- resents a major step forward in improved bridge design and more accurate analysis methods, which will lead to bridges exhibiting superior serviceability, enhanced long-term maintainability, and more uniform levels of safety ‘A discussion of the evolution of the specifications and commentary, including the genesis of the NCHRP project, the research participants, the review process for the specifications, and selected major technical advances in the specifications, is presented in NCHRP Research Results Digest 198 (available from the Transportation Research Board). With the advent of these specifications, bridge engi- neers now have @ choice of two standards to guide their designs, the long-standing AASHTO Standard Specifi- cations for Highway Bridges, and these alternative, newly adopted AASHTO LRFD Bridge Design Specifica- tions, and its companion AASHTO LRFD Bridge Con- struction Specifications.SECTION 1 STRUCTURE EXCAVATION AND BACKFILLLl 12 13 14 1s Table of Contents SPECIFICATIONS AND COMMENTARY GENERAL, WORKING DRAWINGS. MATERIALS. CONSTRUCTION, 1.4.1. Depth of Footings.. 1.42 Foundation Preparation and Control of Water 1.42.1 GENERAL : 1.42.2. EXCAVATIONS WITHIN CHANNELS 1.423 FOUNDATIONS ON ROCK 1.42.4 FOUNDATIONS NOT ON ROCK... 1.42.5 APPROVAL OF FOUNDATION. 1.43 Backfill MEASUREMENT AND PAYMENT 15.1 Measurement... 15.2 Payment...‘SPECIFICATIONS COMMENTARY SECTION 1—STRUCTURE EXCAVATION AND BACKFILL 11 GENERAL Structure excavation shall consist of the removal of all material, of whatever nature, necessary for the con- struction of foundations for bridges, retaining walls, and other major structures in accordance with the contract documents or as directed by the Engineer. If not otherwise provided for in the contract, structure excavation shall include the furnishing of all necessary equipment and the construction and subsequent removal of all cofferdams, shoring, and water control systems which may be necessary for the execution of the work. If not otherwise specified in the contract documents, it shall also include the placement of all necessary backfill, including any necessary stockpiling of excavated mate- rial that is to be used in backfill, and the disposing of excavated material that is not requited for backfill, in roadway embankments or as provided for excess and unsuitable material in AASHTO Guide Specifications for Highway Construction, Subsection 203.02. Tf the contract does not include a separate pay item or items for such work, structure excavation shall include all necessary clearing and grubbing and the removal of existing structures within the area to be excavated. Classification, if any, of excavation will be indicated in the contract documents and set forth in the proposal. ‘The removal and disposal of buried natural or man- ‘made objects are included in the class of excavation in which they are located, unless such removal and disposal are included in other items of work. However, in the case of a buried manmade object, if + its removal requires the use of methods or equip- ‘ment not used for other excavation on the project, + its presence was not indicated in the contract draw- ings, + its presence could not have been ascertained by site investigation, including contact with identified utilities within the area, and + the Contractor so requests in writing prior to its removal. cla Subsection 203.02 is located in the AASHTO Guide Specifications jor Highway Construction, GSH-1, 1993.AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS ‘The removal and disposal of such object will be paid for as extra work, and its volume will not be included in the measured quantity of excavation, 1.2 WORKING DRAWINGS Whenever specified in the contract drawings, the Contractor shall provide working drawings, accompa- nied by calculations where appropriate, of excavation procedures, embankment construction, and backfilling operations, ‘This plan shall show the details of shorit bracing, slope treatment, or other protective system pro- posed for use and shall be accompanied by design calcu. lations and supporting data in sufficient detail to permit ‘an engineering review of the proposed design. ‘The working drawings for protection from caving shall be submitted sufficiently in advance of proposed use to allow for their review, revision, if needed, and approval without delay to the work. ‘Working drawings shall be approved by the Engineer prior to performance of the work involved, and such approval shall not relieve the Contractor of any responsi- bility under the contract for the successful completion of the work, 13. MATERIALS Material used for backfill shall be free of frozen lumps, wood, of other degradable or hazardous matter, and shall be of a grading such that the required compac- tion can be consistently obtained using the compaction ‘methods selected by the Contractor. Permeable material for underdrains shall conform to AASHTO Guide Specifications for Highway Construc- tion, Subsection 70401. 1.4 CONSTRUCTION 14.1 Depth of Footings ‘The elevation of the bottoms of footings, as shown in the contract documents, shall be considered as approxi- mate only and the Engineer may order, in writing, such ‘changes in dimensions or elevation of footings as may be necessary to secure a satisfactory foundation, 1.4.2 Foundation Preparation and Control of Water 1.42.1 GENERAL ‘Where possible, all substructures shall be constructed in open excavation and, where necessary, the excavation COMMENTARY. 13 Subsection 704.01 is located in the AASHTO Guide ‘Specifications for Highway Construction, GSH-7, 1993.SPECIFICATIONS Section 1—Structure Excavation and Backfill COMMENTARY shall be shored, braced, or protected by cofferdams con- structed in accordance with the requirements contained in Article 3.3, “Cofferdams and Shoring.” When footings can be placed in the dry without the use of cofferdams, backforms may be omitted with the approval ofthe Engi- reer, and the entire excavation filled with concrete to the required elevation of the top of the footing. The addi- tional concrete required shall be furnished and placed at the expense of the Contractor. Temporary water control systems shall conform to the requirements contained in Anticle 3.4, “Temporary Water Control Systems. 1.42.2 EXCAVATIONS WITHIN CHANNELS ‘When excavation encroaches upon a live streambed or channel, unless otherwise permitted, no excavation shall be made outside of caissons, cribs, cofferdams, steel piling, or sheeting, and the natural streambed adja- cent to the structure shall not be disturbed without per- mission from the Engineer. If any excavation or dredging is made at the site of the structure before caissons, cribs, or cofferdams are sunk or are in place, the Contractor shall, without extra charge, after the foundation base is in place, backfill all such excavation to the original ground surface or riverbed with material satisfactory to the Engi- ner. Material temporarily deposited within the flow area of streams from foundation or other excavation shall be removed and the stream flow area freed from obstruction thereby. 1.423 FOUNDATIONS ON ROCK ‘When a foundation is to rest on rock, the rock shall be freed from all loose material, cleaned, and cut to a firm surface, either level, stepped, or roughened, as may be directed by the Engineer. All seams shall be cleaned out and filled with concrete, mortar, or grout before the foot- ing is placed. ‘Where blasting is required to reach footing level, any loose, fractured rock caused by overbreak below bearing level shall be removed and replaced with concrete or grouted at the Contractor’s expense. 1.42.4 FOUNDATIONS NOT ON ROCK ‘When a foundation is to rest on an excavated surface ‘other than rock, special care shall be taken not to disturb the bottom of the excavation, and the final removal of the foundation material to grade shall not be made until just before the footing is to be placed. Where the material below the bottom of footings not supported by piles has been disturbed, it shall be removed and the entire space filled with concrete orAASHTO LRED Bridge Construction Specifications SPECIFICATIONS other approved material at the Contractor's expense. Under footings supported on piles, the over-excavation or disturbed volumes shall be replaced and compacted as directed by the Engineer. 1.425 APPROVAL OF FOUNDATION ‘After each excavation is completed, the Contractor shall notify the Engineer that the excavation is ready for inspection and evaluation, and no concrete or other foot- jing material shall be placed until the Engineer has approved the depth of the excavation and the character of the foundation material. 143° Backfill Backfill material shall conform to the provisions of Article 1.3, “Materials.” If sufficient material of suitable quality is not available from excavation within the project limits, the Contractor shall import such material as directed by the Engineer. Unless otherwise specified in the contract documents, all spaces excavated and not occupied by abutments, piers, or other permanent work shall be refilled with earth up to the surface of the surrounding ground, with a sufficient allowance for settlement. Except as otherwise provided, all backfill shall be thoroughly compacted to the density of the surrounding ground, and its top surface shall be neatly graded. Fill placed around piers shall be deposited on both sides to approximately the same eleva- tion at the same time. Rocks larger than 75 mm maxi- ‘mum dimension shall not be placed against the concrete surfaces. Embankment construction shall conform to the requirements of AASHTO Guide Specifications for High way Construction, Subsection 203.02. The fill at retain- ing walls, abutments, wingwalls, and all bridge bents in embankment shall be deposited in well-compacted, hori- zontal layers not to exceed 1.50 mm in thickness and shall be brought up uniformly on all sides of the structure or facility. Backfill within or beneath embankments, within the roadway in excavated areas, or in front of abutments, and retaining walls or wingwalls shall be compacted to the same density as required for embankments, No backfill shall be placed against any concrete strue- ture until permission has been given by the Engineer. ‘The placing of such backfill shall also conform to the requirements of Article 8.15.2, “Earth Loads.” The back- fill in front of abutments and wingwalls shall be placed first to prevent the possibility of forward movement, Jet- ting of the fill behind abutments and wingwalls will not bbe permitted. La COMMENTARY C143 Subsection 203.02 is located in AASHTO Guide Spec- ‘ications for Highway Construction, GSH-7, 1993.SPECIFICATIONS Section I—Structure Excavation and Backfill COMMENTARY Adequate provision shall be made for the thorough drainage of all backfill. French drains, consisting of at least 0.06 m* of permeable material wrapped in filter fab- ric to prevent clogging and transmission of fines from the backfill, shall be placed at each weep hole. Backfilling of metal and concrete culverts shall be done in accordance withthe requirements of Sections 26, "Metal Culverts,” and 27, “Concrete Culverts. 1,5 MEASUREMENT AND PAYMENT 1.5.1 Measurement The quantity to be paid for as structure excavation shall be measured by the cubic meter. The quantities for payment will be determined from limits shown in the contract documents or ordered by the Engineer. No deduction in structure excavation pay quantities will be made where the Contractor does not excavate material that is outside the limits of the actual structure but within the limits of payment for structure excavation. Unless otherwise specified in the contract documents, pay limits for structure excavation shall be taken as: + the horizontal limits shall be vertical planes 450 ‘mm outside of the neat lines of footings or struc tures without footings, + the top limits shall be the original ground or the top Of the required grading cross-section, whichever is. lower, and + the lower limits shall be the bottom of the footing or base of structure, or the lower limit of excava- tion ordered by the Engineer. ‘When foundations are located within embankments ‘and the specifications require the embankment to be con- structed to a specified elevation that is above the bottom of the footing or base of structure prior to construction of the foundation, then such specified elevation will be con- sidered to be the original ground. ‘When it is necessary, in the opinion of the Engineer, to carry the foundations below the elevations shown in the contract documents, the excavation for the first’ 900 ‘mm of additional depth will be included in the quantity for which payment will be made under this item, Excava- tion below this additional depth will be paid for as extra work, unless the Contractor states in writing that pay- ‘ment at contract prices is acceptable.AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS 1.5.2 Payment Unless otherwise provided, structure excavation, ‘measured as provided in Article 1.5.1, “Measurement,” will be paid for by the cubic meter for the kind and class specified in the contract documents. Payment for structure excavation shall include full compensation for all labor, material, equipment, and other items that may be necessary or convenient to the ‘successful completion of the excavation to the elevation of the bottom of footings or base of structure, Full compensation for controlling and removing water from excavations and for furnishing and installing or constructing all cofferdams, shoring, and all other facili ties necessary to the operations, except concrete seal courses that are shown in the contract documents, and their subsequent removal, shall be considered as included in the contract price for structure excavation, unless the contract document provides for their separate payment, Unless otherwise specified in the contract documents, the contract price for structure excavation shall include full payment for all handling and storage of excavated ‘materials that are to be used as backfill, including any necessary drying, and the disposal of all surplus or unsuitable excavated materials. Any clearing, grubbing, or structure removal that is required, but not paid for under other items of the contract documents, will be con- sidered to be included in the price paid for structure excavation, Unless the contract document provides for its separate payment, the contract price for structure excavation shall include full compensation for the placing and compact- ing of structure backfill. The furnishing of backfill mate- rial from sources other than excavation will be paid for at the contract unit price for the material being used, or as, extra work if no unit price has been established. COMMENTARYSECTION 2 REMOVAL OF EXISTING STRUCTURESTable of Contents SPECIFICATIONS AND COMMENTARY DESCRIPTION WORKING DRAWINGS..... CONSTRUCTION. 23.1 General. 23.2 Salvage. . 23.3 Partial Removal of Structures 234 Disposal MEASUREMENT AND PAYMENT iliSPECIFICATIONS COMMENTARY SECTION 2—REMOVAL OF EXISTIN STRUCTURES 21 DESCRIPTION ‘This work shall consist of the removal, wholly or in part, and satisfactory disposal or salvage of all bridges, retaining walls, and other major structures that are desig. nated to be removed in the contract documents. Unless otherwise specified, the work also includes any neces- sary excavation and the backfilling of trenches, holes, or pits that result from such removal. It also includes all costs for environmental and health monitoring systems (programs as may be required. 2.2. WORKING DRAWINGS Working drawings showing methods and sequence of removal shall be prepared + when structures or portions of structure are speci- fied to be removed and salvaged, ‘+ when removal operations will be performed over ‘or adjacent to public traffic or railroad property, or + when specified in the contract documents. ‘The working drawings shall be submitted to the Engi- reer for approval at least 10 days prior to the proposed start of removal operations. Removal work shall not begin until the drawings have been approved. Such approval shall not relieve the Contractor of any responsi bility under the contract documents for the successful completion of the work. ‘When salvage is required, the drawings shall clearly indicate the markings proposed to designate individual segments of the structure. 23 CONSTRUCTION 23.1 General Except for utilities and other items that the Engineer ‘may direct the Contractor to leave intact, the Contractor shall raze, remove, and dispose of each structure or por- tion of structure designated to be removed. All concrete a4AASHTO LRED Bridge Construction Specifications SPECIFICATIONS and other foundations shall be removed to a depth of at Teast 600 mm below ground elevation or 900 mm below subgrade elevation, whichever is lower. Unless other- wise specified in the contract documents, the Contractor hhas the option either to pull piles or cut them off at a point not less than 600 mm below groundline. Cavities left from structure removal shall be backfilled to the level of the surrounding ground and, if within the area of roadway construction, shall be compacted to meet the requirements of the contract documents for embankment. slosives shall not be used except at locations and under conditions specified in the contract documents. All blasting shall be completed before the placement of new work. 23.2 Salvage ‘Materials that are designated to be salvaged under the contract documents, either for reuse in the project or for future use by the Owner, shall remain the property of the Owner and shall be carefully removed in transportable sections and stockpiled near the site at a location desig- nated by the Engineer. The Contractor shall restore or replace damaged or destroyed material without addi- tional compensation. Rivets and bolts that must be removed from steel structures to be salvaged shall be removed either by cut- ting the heads with a chisel, after which they shall be punched of drilled from the hole, or by any other method ‘that will not injure the members for reuse and will meet with the approval of the Engineer. Prior to dismantling, all members or sections of steel structures shall be ‘match-marked with paint in accordance with the diagram oo plan approved by the Engineer. All bolts and nails shall be removed from lumber deemed salvageable by the Engineer as part of the sal- vage of timber structures. 23.3 Partial Removal of Structures When structures are to be widened or modified and only portions of the existing structure are to be removed, these portions shall be removed in such a manner as to leave the remaining structure undamaged and in proper condition for the use contemplated. Methods involving the use of blasting or wrecking balls shall not be used within any span or pier unless the entire span or pier is to bbe removed. Any damage to the portions remaining in service shall be repaired by the Contractor at the Con- tractor's expense. Before beginning concrete removal operations involv- ing the removal of a portion of a monolithic concrete ele- ‘ment, a saw cut approximately 25 mm deep shall be 2.2 COMMENTARY 2323 SPECIFICATIONS ‘Section 2—Removal of Existing Structures COMMENTARY. ‘made to a true line along the limits of removal on all faces of the element that will be visible in the completed work. Old concrete shall be carefully removed to the lines designated by drilling, chipping, or other methods approved by the Engineer. The surfaces presented as a result of this removal shall be reasonably true and even, with sharp straight comers that will permit a neat joint with the new construction or be satisfactory for the use contemplated. Where existing reinforcing bars are to cextend from the existing structure into new construction, the concrete shall be removed so as to leave the project” ing bars clean and undamaged. Where projecting bars are not to extend into the new construction, they shall be cut off flush with the surface of the old concrete During full-depth removal of deck concrete over ste! ‘beams or girders that are to remain in place, the Contrac- tor shall exercise care so as not to notch, gouge, or distort the top flanges. Any damage shall be repaired at the direction of the Engineer and at the expense of the Con- tractor. Repairs may include grinding, welding, heat straightening, or member replacement, depending on the location and severity of the damage. 23.4 Disposal ‘Any material not designated for salvage will belong to the Contractor. Except as provided herein, the Contractor shall store or dispose of such material outside of the right-of-way. If the material is disposed of on private property, the Contractor shall secure written permission from the property owner and shall furnish a copy of each agreement to the Engineer. Waste materials may be dis- posed of in an Owner’s site when such sites are described in the contract documents. Unless otherwise provided in the contract documents, removed concrete may be buried in adjacent embank- ‘ments, provided it is broken into pieces that can be readily handled and incorporated into embankments and is placed at a depth of not less than 900 mm below fir ished grade and slope lines. The removed concrete shall not be buried in areas where piling is to be placed or within 3000 mm of trees, pipelines, poles, buildings, or other permanent objects or structures, unless permitted by the Engineer. Removed concrete may also be dis- posed of outside the right-of-way as provided above. ‘The contract documents shall indicate all known haz- ardous material including paint history. Hazardous mate- rial shall be properly disposed of and appropriate records maintained. 23AASHTO LRFD Bridge Construction Specifications ‘SPECIFICATIONS 2.4 MEASUREMENT AND PAYMENT ‘The work, as prescribed for by this item, shall be mea- sured as each individual structure or portion of a struc- ture to be removed. Payment will be made on the basis of the lump sum bid price for the removal of each structure ‘portion of structure as specified in the contract docu- ments. ‘The above prices and payments shall be full compen- sation for all work, labor, tools, equipment, excavation, backfilling, materials, proper disposal, and incidentals necessary to complete the work, including salvaging materials not to be reused in the project when such sal- vaging is specified and not otherwise paid for. Faull compensation for removing and salvaging mate- rials that are to be reused in the project shall be consid cred as included in the contract document prices pai reconstructing, relocating, or resetting the involved, or in such other contract pay items as may be designated in the contract documents; no additional com- pensation will be allowed therefor. 24 COMMENTARY 24SECTION 3 TEMPORARY WORKSTable of Contents SPECIFICATIONS AND COMMENTARY 31 GENERAL 3.1.1 Description. 3.4.2, Working Drawiny 3.2 FALSEWORK AND FORMS.. 3.2.1 Gener: 3.2.2. Falsework Design and Construction..... 33 3.2.2.1 LOADS.. 33 3.2.2.2 FOUNDATIONS. 3.22.3. DEFLECTIONS. 3.2.2.4 CLEARANCES € 3.2.2.5 CONSTRUCTIO} = 323 Formwork Design and Construction. 3.23.1 GENERAL. 3.23.2 DESIGN. 3.23.3 CONSTRUCTION. 3.23.4 TUBE FORMS .. 3.23.5 STAY-IN-PLACE FORMS 3.2.4 Removal of Falsework and Forms. 3.2.4.1 GENERAL. 3.2.4.2 TIME OF REMOVAL. 3.2.4.3 EXTENT OF REMOVAL... 3.3. COFFERDAMS AND SHORING 3.3.1 General. 3.4 TEMPORARY WATER CONTROL SYSTEMS. 310 34.1 General. 3.4.2. Working Drawings... 343 Operations 3.3.5 TEMPORARY BRIDGE! 35.1 General .. 352 Detour Bridges 35.3. Haul Bridges. 38.4 Maintenance 3.6 MEASUREMENT AND PAYMENT. BivSPECI COMMENTARY SECTION 3—TEMPORARY WORKS 3.1 GENERAL. 3.1.1 Description ‘This work shall consist of the construction and removal of temporary facilities that are generally designed by the Contractor and employed by the Con- tractor in the execution of the work, and whose failure to perform properly could adversely affect the character of the contract work or endanger the safety of adjacent facilities, property, or the public. Such facilities include, but are not limited to, falsework, forms and form travel- ers, cofferdams, shoring, water control systems, and tem- porary bridges. Appropriate reductions in allowable stresses and decreases in resistance factors or imposed loads shall be used for design when other than new or undamaged materials are to be used. To the extent possi- ble, calculations shall include adjustments to section Properties to account for damage or section loss. Unless otherwise permitted, the design of the tempo- rary works shall be based on AASHTO LRED Bridge Design Specification load factors specified in Articles 3.4.1 and 3.4.2, and all applicable load combinations shall be investigated. 31 C314 FHWA issued Technical Advisory T5140.24 on Octo- ber 29, 1993, concerning BRIDGE TEMPORARY WORKS. The Secretary of the U.S. Department of ‘Transportation was directed by Congress to develop specifications and guidelines for use in constructing bridge temporary works. The falsework collapse of the Maryland Route 198 Bridge over the Baltimore/Wash- ington Parkway and the fact that no national standard code or specification was available on bridge temporary ‘works precipitated the mandate. ‘The guide specifications, handbook, and certification program are useful in conjunction with Section 3, “Tem- porary Works,” of the LRFD Bridge Construction Speci- fications. States are encouraged to review these publications and incorporate appropriate portions into their specifications. The Construction Handbook is a use- ful instructional tool for field inspection personnel. ‘The following publications are useful reference docu- ‘ments in the preparation of specifications for the design, review, and inspection of temporary works: + Synthesis of Falsework, Formwork, and Seaffold- ing for Highway Bridge Structures, November 1991 (FHWA-RD-91-062) + Guide Standard Specifications for Bridge Tempo- rary Works, November 1993 (FHWA-RD-93- 03) + Guide Design Specifications for Bridge Temporary Works, November 1993 (FHWA-RD-93-032) * Certification Program for Bridge Temporary Works, November 1993 (FHWA-RD-93-033) + Construction Handbook for Bridge Temporary ‘Works, November 1993 (FHWA-RD-93-034)AASHTO LRED Bridge Construction Specific: SPECIFICATIONS 3.1.2 Working Drawings Whenever specified in the contract documents or requested by the Engineer, the Contractor shall provide working drawings with design calculations and suppor ing data in sufficient detail to permit a structural review of the proposed design of a temporary work. When con- crete is involved, such data shall include the sequence and rate of placement. Sufficient copies shall be fur- nished to meet the needs of the Engineer and other enti ties with review authority. The working drawings shall be submitted sufficiently in advance of proposed use to allow for their review, revision if needed, and approval without delay to the work. ‘The Contractor shall not start the construction of any temporary work for which working drawings are required until the drawings have been approved by the Engineer. Such approval will not relieve the Contractor of responsibility for results obtained by use of these drawings or any of the Contractor's other responsibilities under the contract. 3.13. Design ‘The design of temporary works shall conform to the AASHTO LRFD Bridge Design Specifications or the Guide Design Specifications for Bridge Temporary Works, ot to other established and generally accepted design code or specification for such work. ‘When manufactured devices are to be employed, the design shall not result in loads on such devices in excess of the load ratings recommended by their manufacturer, For equipment where the rated capacity is determined by load testing, the design load shall be as stated in the Guide Specifications for Bridge Temporary Works. ‘The load rating used for special equipment, such as access scaffolding, may be under the jurisdiction of OSHA and/or other State/local regulations. However, in ‘no case shall the rating exceed 80 percent of the maxi- ‘mum load sustained during load testing of the equip- ‘ment. ‘When required by statute or specified in the contract, documents, the design shall be prepared and the draw- ings signed by a Registered Professional Engineer. 3-2 3.1 COMMENTARY ‘The General Description of Temporary Works refers to AASHTO LRED Bridge Design Specifications, 1994, Article 3.4.1, “Load Factors and Load Combinations,” and Article 3.4.2, “Load Factors for Construction Loads.” 313 Article 3.1.3 specifies the use of the AASHTO LRFD Bridge Design Specifications or the Guide Design Speci- fications for Bridge Temporary Works, unless another recognized specification is accepted by the Engineer, ‘The Guide Design Specifications for Bridge Tempo- rary Works is referenced for design loads. ‘Access scaffolding is covered under the Occupational Safety and Health Administration (OSHA), but stability trusses used for erection of structural steel are designed as falsework.32 ‘SPECIFICATIONS Section 3—Temporary Works COMMENTARY 3.14 Construction ‘Temporary works shall be constructed in conform- lance with the approved working drawings. The Contrac- tor shall verify that the quality of the mater ‘employed are consistent with that assumed 315 Removal Unless otherwise specified, all temporary works shall be removed and shall remain the property of the Contrac- tor upon completion of their use. The area shall be restored to its original or planned condition and cleaned of all debris. 3.2. FALSEWORK AND FORMS 324 General ‘The working drawings for falsework shall be prepared and sealed by a Registered Professional Engineer when- ever the height of falsework exceeds 4300 mm or when- ever traffic, other than workers involved in constructing, the bridge, wll travel under the bridge Falsework and forms shal be of sufficient rigidity and strength to safely support all loads imposed and to pro- duce inthe finished structure the lines and grades indi- cated in the contract documents. Forms shall also impart the required surface texture and nistcation, and shall not detract from the uniformity of color of the formed sur- faces. 32.2 Falsework Design and Construction 3.2.2.1 LOADS The design load for falsework shall consist ofthe sum of dead and live vertical loads and any horizontal loads. ‘As a minimum, dead loads shall include the mass of the falsework and all construction material to be sup- ported. The combined density of conerete, reinforcing and prestressing steel, and forms shall be assumed to be not less than 2560 kg/m? of normal-density concrete oF 2080 kg/m? of low-density concrete that is supported. Live loads shall consist of the actual mass of any equipment to be supported applied as concentrated loads at the points of contact and a uniform load of not less than 0.001 MPa applied over the area supported, plus 1.10 N/mm applied at the outside edge of deck over- hangs. The horizontal load used for the design of the false- work bracing system shall be the sum of the horizontal loads due to equipment, construction sequence (includ- 3-3 324 Falsework is considered to be any temporary structure that supports structural elements of concrete, steel, ‘masonry, or other materials during their cnstruction or erection. Forms are considered to be the enclosures or panels that contain the fluid concrete and withstand the forces due to its placement and consolidation. Forms may in ‘tum be supported on falsework, Form travelers, as used in segmental cantilever con- struction, are considered to be a combination of false- work and forms. 3.22.1 In the customary U.S. units, normal-density concrete is known as normal weight concrete and low-density ‘concrete is known as lightweight concrete,AASHTO LRED Bridge Construction Specifications SPECIFICATIONS COMMENTARY. 32 ing unbalanced hydrostatic forces from fluid concrete), stream flow when applicable, and an allowance for wind. However, in no case shall the horizontal load to be resisted in any direction be less than 2 percent of the total dead load. For post-tensioned structures, the falsework shall also bbe designed to support any increase or redistribution of loads caused by prestressing of the structure. Loads imposed by falsework onto existing, new, or partially completed structures shall not exceed those per- mitted in Article 8.15, “Application of Loads. 3.2.2.2 FOUNDATIONS Falsework shall be founded on a solid footing safe against undermining, protected from softening, and capa- ble of supporting the loads imposed on it. When requested by the Engineer, the Contractor shall demon- strate by suitable load tests that the soil bearing values assumed for the design of the falsework footings do not exceed the supporting capacity of the sol. Falsework that cannot be founded on a satisfactory footing shall be supported on piling that shall be spaced, driven, and removed in an approved manner. 3.2.2.3 DEFLECTIONS For cast-in-place concrete structures, the calculated deflection of falsework flexural members shall not exceed 1/240 of their span irrespective ofthe fact thatthe deflection may be compensated for by camber strips. 3.2.2.4 CLEARANCES Unless otherwise provided, the minimum dimensions of clear openings to be provided through falsework for roadways that are to remain open to traffic during con- struction shall be atleast 1500 mm greater than the width of the approach traveled way, measured between barriers when used. The minimum vertical clearance over inter- state routes and freeways shall be 4420 mm, and 4270 1mm over other classes of roadways. 3.2.2.5 CONSTRUCTION Falsework shall be constructed and set to grades that allow for its anticipated settlement and deflection, and for the vertical alignment and camber indicated in the contract documents or ordered by the Engineer for the Permanent structure. When directed by the Engineer, variable-depth camber strips shall be used between false- work beams and soffit forms to accomplish this 3-432 SPECIFICATIONS ‘Section 3—Temporary Works COMMENTARY Suitable screw jacks, pairs of wedges, or other devices shall be used at each post to: + adjust falsework to grade, + permit minor adjustments during the placement of concrete or structural steel should observed settle- ‘ments deviate from those anticipated, and + allow for the gradual release of the falsework.. ‘The Contractor shall provide for accurate measurement of falsework settlement during the placing and curing of the concrete. Falsework or formwork for deck slabs on girder bridges shall be supported directly on the girders so that there will be no appreciable differential settlement dur- ing placing of the concrete. Girders shal either be braced and tied to resist any forces that would cause rotation oF torsion in the girders caused by the placing of concrete for diaphragms or decks, or be shown to be adequate for those effects. Unless specifically permitted, welding of falsework support brackets or braces to structural stee! ‘members or reinforcing steel shall not be allowed. 3.2.3 Formwork Design and Construction 323.1 GENERAL Forms shall be of wood, steel, or other approved ‘material and shall be mortar tight and of sufficient rgid- ity to prevent objectionable distortion of the formed con. crete surface caused by pressure of the concrete and other Toads incidental tothe construction operations. Forms for concrete surfaces exposed to view shall produce a smooth surface of uniform texture and color substantially equal to that which would be obtained with the use of plywood conforming to the National Institute of Standards and Technology Product Standard PSI for Exterior B-B Class I Plywood. Panels ining such forms shall be arranged so that the join lines form a symmet- cal pattern conforming to the general lines of the struc- ture. The same type of form-lining material shall be used throughout each element of a structure. Such forms shall be sufficiently rigid so thatthe undulation ofthe concrete surface shall not exceed 3 mm when checked with » 1500 mm straightedge or template. All sharp comers shall be filleted with approximately 20 mm chamfer strips Concrete shall not be deposited in the forms until all ‘work connected with constructing the forms has been completed, all debris has been removed, all materials to bbe embedded in the concrete have been placed for the unit to be east, and the Engineer has inspected the forms and materials. 3.5 3.23.1 Forms for concrete structures using plywood refers to the National Institute of Standards and Technology Prod- uct Standards PSI.AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS 3.23.2 DESIGN ‘The structural design of formwork shall conform to ACI Standard, “Recommended Practice for Conerete Formwork” (ACI 347), or some other generally accepted and permitted standard, In selecting the hydrostatic pres- sure to be used in the design of forms, consideration shall be given to the maximum rate of concrete placement to be used, the effects of vibration, the temperature of the concrete, and any expected use of set-retarding admix- tures or pozzolanic materials in the concrete mix. 3.233 CONSTRUCTION Forms shall be set and held true to the dimensions, lines, and grades of the structure prior to and during the placement of concrete. Forms may be given a bevel or draft at projections, such as copings, to ensure easy removal. Prior to reuse, forms shall be cleaned, inspected for damage, and, if necessary, repaired. When forms appear to be defective in any manner, either before or during the placement of concrete, the Engineer may ‘order the work stopped until defects have been corrected, Forms shall be treated with form oil or other approved release agent before the reinforcing steel is placed. Mate- rial that will adhere to or discolor the concrete shall not beused. Except as provided herein, metal ties or anchorages within the forms shall be so constructed as to permit their removal to a depth of at least 25 mm from the face with- out injury to the concrete. Ordinary wire ties may be used only when the concrete will not be exposed to view and where the concrete will not come into contact with salts or sulfates. Such wire ties, upon removal of the forms, shall be cut back at least 6 mm from the face of the concrete with chisels or nippers; for green concrete, rippers shall be used. Fittings for metal ties shall be of such design that, upon their removal, the cavities that are left will be of the smallest possible size, The cavities shall be filled with cement mortar and the surface left sound, smooth, even, and uniform in color. When epoxy-coated reinforcing steel is required, all ‘metal ties, anchorages, or spreaders that will remain in the conerete shall be of corrosion-resistant material or coated with a dielectric material. For narrow walls and columns where the bottom of the form is inaccessible, an access opening shall be pro- vided in the forms for cleaning out extraneous material immediately before placing the concrete. 3.6 32 COMMENTARY 3.232 Formwork design refers to ACI 347-78, “Recom- ‘mended Practice for Concrete Formwork.”32 SPECIFICATIONS ‘Section 3—Temporary Works COMMENTARY 3.23.4 TUBE FORMS Tubes used as forms to produce voids in concrete slabs shall be properly designed and fabricated or other- wise treated to make the outside surface waterproof. Prior to concrete placement, such tubes shall be pro- tected from the weather and stored and installed by meth ‘ods that prevent distortion or damage. The ends of tbe forms shall be covered with caps that shall be made mor- tar tight and waterproof. If wood or other material that expands when moist is used for capping tubes, a pre- ‘molded rubber joint filler 6 mm in thickness shall be used around the perimeter of the caps to permit expan- sion. A polyvinyl chloride (PVC) vent tube shall be pro- vided near each end of each tube. These vents shall be constructed to provide positive venting of the voids. ‘After exterior form removal, the vent tube shall be ‘trimmed to within 15 mm of the bottom surface of the finished concrete. Anchors and ties for tube forms shall be adequate to prevent displacement of the tubes during concrete place- ment. 3.2.35 STAY-IN-PLACE FORMS, Stay-in-place deck soffit forms, such as corrugated ‘metal or precast concrete panels, may be used if shown in the contract documents or approved by the Engineer. Prior to the use of such forms, the Contractor shall pro- vide a complete set of details to the Engineer for review and approval. Unless otherwise noted, the contract docu- ‘ments for structures should be dimensioned for the use of removable forms. Any changes necessary to accommo: date stay-in-place forms, if approved, shall be at the expense of the Contractor. 324 Removal of Falsework and Forms 3.2.4.1 GENERAL Falsework or forms shall not be removed without approval of the Engineer. In the determination of the time for the removal of falsework and forms, consider- ation shall be given to the location and character of the structure, the weather, the materials used in the mix, and other conditions influencing the early strength of the concrete. Methods of removal likely to cause overstressing of the concrete or damage to its surface shall not be used. Supports shall be removed in such a manner as to permit the structure to uniformly and gradually take the stresses due to its own mass. For structures of two or more spans, 3-7AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS the sequence of falsework release shall be as specified or approved in the contract documents. 3.2.42 TIME OF REMOVAL. If field operations are not controlled by beam or eylin- der tests, the following minimum periods of time, exclu- sive of days when the temperature is below 5°C, shall have clapsed after placement of concrete before false- work is released or forms are removed: Falsework for: Spans over 4270 mm 14 days Spans of 4270 mm or less 10 days Bent caps not yet supporting girders 10 days Forms [Not supporting the dead mass of the concrete 24 hours For interior cells of box girders and for railings 12hours If high early strength is obtained with Type III cement ‘by the use of additional cement, these periods may be reduced as directed. Where field operations are controlled by cylinder tests: + Generally, the removal of supporting forms or falsework shall not begin until the concrete is found to have the specified compressive strength. ‘+ Inno case shall supports be removed in less than 7 ‘days after placing the concrete. + Forms shall not be removed until the concrete has sufficient strength to prevent damage to the sur- face. + Falsework for post-tensioned portions of structures shall not be released until the prestressing steel has been tensioned. + Falsework supporting any span of a continuous or rigid frame bridge shall not be released until the aforementioned requirements have been satisfied forall of the structural concrete in that span and in the adjacent portions of each adjoining span for a length equal to at least one-half the length of the span where falsework is to be released, Unless otherwise specified or approved in the contract documents, falsework shall be released before the rail- ings, copings, or barriers are placed for all types of bridges. For arch bridges, the time of falsework release COMMENTARY 3233 ‘SPECIFICATIONS relative to the construction of elements of the bridge above the arch shall be as shown in the contract docu- ‘ments or as directed by the Engineer. 3.2.43 EXTENT OF REMOVAL All falsework and forms shall be removed except: + Portions of driven falsework piles that are more than 300 mm below subgrade within roadbeds, 600 mm below the original ground or finished grade ‘outside of roadbeds, or 600 mm below the estab- lished limits of any navigation channel, + Footing forms where their removal would endan- ger the safety of cofferdams or other work. + Forms from enclosed cells where access is not pro- vided. + Deck forms in the cells of box girder bridges that do not interfere with the future installation of uti ties shown in the contract documents. 33 COFFERDAMS AND SHORING 33.1 General Cofferdams shall be constructed to adequate depths to censure stability and to adequate heights to seal off all water. They shall be safely designed and constructed, and be made as watertight as is necessary for the proper performance of the work that must be done inside them. In general, the interior dimensions of cofferdams shall be such as to give sufficient clearance for the construction of forms and the inspection of their exteriors, and to per- ‘mit pumping from outside the forms. Cofferdams that are tilted or moved laterally during the process of sinking shall be righted, reset, or enlarged so as to provide the necessary clearance. This shall be solely at the expense of the Contractor. The Contractor shall control the ingress of water so that footing concrete can be placed in the dry. The Con: tractor shall determine if a seal is required, and if required, shall determine the depth of the seal and the cure time required, and shall be fully responsible for the performance of the seal. After the seal has cured, the cof- ferdam shall be pumped out and the balance of the masonry placed in the dry. When weighted cofferdams are employed and the weight is utilized to partially over- come the hydrostatic pressure acting against the bottom of the foundation seal, special anchorage such as dowels, or keys shall be provided to transfer the entire weight of the cofferdam into the foundation seal. During the Section 3—Temporary Works COMMENTARY 0334 Cofferdams and shoring consist of those structures used to temporarily hold the surrounding earth and water out of excavations and to protect adjacent property and facilities during construction of the permanent work. ‘A concrete seal conforming to the requirements of Section 8, “Concrete Structures,” shall be placed under- ‘water below the elevation of the footing.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS placing and curing of a foundation seal, the elevation of the water inside the cofferdam shall be controlled to pre- vent any flow through the seal, and if the cofferdam is to remain in place, it shall be vented or ported at or below Tow water level Shoring shall be adequate to support all loads imposed and shall comply with any applicable safety regulations. 3.3.2. Protection of Concrete Cofferdams shall be constructed so as to protect green concrete against damage from sudden fluctuations in water level and to prevent damage to the foundation by erosion. No struts or braces shall be used in cofferdams or shoring systems in such a way as to extend into or through the permanent work, without written permission from the Engineer. 3.3.3 Removal Unless otherwise provided or approved, cofferdams and shoring with all sheeting and bracing shall be removed after the completion of the substructure, with care being taken not to disturb or otherwise injure the finished work. 3.4 TEMPORARY WATER CONTROL SYSTEMS 34.1 General ‘Temporary water control systems consist of dikes, bypass channels, flumes and other surface water diver- sion works, cut-off walls, and pumping systems, includ- ing wellpoint and deep well systems, used to prevent water from entering excavations for structures. 342 Working Drawings Working drawings for temporary water control sys- tems, when required, shall include details of the design and the equipment, operating procedures to be employed, and location of point or points of discharge. The design and operation shall conform to all applicable water polli- tion and erosion control requirements. 343° Operations Pumping from the interior of any foundation enclo- sure shall be done in such manner as to preclude the pos- ibility of the movement of water through any fresh concrete. No pumping will be permitted during the COMMENTARY 3435 SPECIFICATIONS Section 3—Temporary Works COMMENTARY placing of concrete or for a period of at least 24 hours thereafter, unless it is done from a suitable sump sepa- rated from the concrete work by a watertight wall corother effective means, subject to approval of the Engineer. Pumping to unwater a sealed cofferdam shall not ‘commence until the seal has set sufficiently to withstand the hydrostatic pressure. Pumping from wellpoints or deep wells shall be regu- lated 50 as to avoid damage by subsidence to adjacent Property. 3.5 TEMPORARY BRIDGES 3.51 General ‘Temporary bridges shall be constructed, maintained, and removed in @ manner that will not endanger the work cr the public. 3.5.2 Detour Bridges When a design is furnished by the Owner, detour bridges shall be constructed and maintained to conform to either such design or an approved alternative design. When permitted by the specifications, the Contractor may submit a proposed altemative design. Any alterna- tive design must be equivalent in all respects to the design and details furnished by the Owner and is subject, to approval by the Engineer. The working drawings and design calculations for any alternative design shall be signed by a Registered Professional Engineer ‘When a design is not furnished by the Owner, the Contractor shall prepare the design and furnish working drawings to the Engineer for approval. The design shall provide the clearances, alignment, load capacity, and other design parameters specified or approved in the con- tract documents. The design shall conform to the AASHTO LRFD Bridge Design Specifications. If design live loads are not otherwise specified in the contract doc- uments, 75 percent of the HIL93 loading may be used. ‘The working drawings and design calculations shall be signed by a Registered Professional Engineer. 35.3 Haul Bridges When haul road bridges or other bridges that are not for public use are proposed for construction over any right-of-way that is open to the public or that is over any railroad, working drawings showing complete design and details, including the maximum loads to be carried, shall be submitted to the Engineer for approval. Such drawings shall be signed by a Registered Professional 3S. ‘Temporary bridges include detour bridges for use by the public, haul road bridges, and other structures, such as conveyor bridges, used by the Contractor. 382 ‘The design of detour bridges refers to the AASHTO LRFD Bridge Design Specifications, 1994. 383 ign of haul bridges refers to the AASHTO LRFD Bridge Design Specifications, 1994,AASHTO LRED Bridge Construction Specifications SPECIFICATIONS COMMENTARY. 36 Engineer. The design shall conform to AASHTO LRFD Bridge Design Specifications when applicable or to other appropriate standards. 3.5.4 Maintenance ‘The maintenance of temporary bridges for which working drawings are required shall include their replacement in case of partial or complete failure. In case of the Contractor's delay or inadequate progress in mak- ing repairs and replacement, the Owner reserves the right to furnish such labor, materials, and supervision of the work as may be necessary to restore the structure for proper movement of traffic. The entire expense of such restoration and repairs shall be considered a part of the cost of the temporary structure and where such expendi- tures are incurred by the Owner, they shall be charged to the Contractor. 3.6 MEASUREMENT AND PAYMENT. Unless otherwise specified in the contract documents, payment for temporary works shall be considered to be included in the payment for the various items of work for which they are used and no separate payment shall be ‘made therefor. When an item for concrete seals for cofferdams is included in the contract, such concrete will be measured and paid for as provided in Section 8, “Concrete Struc- tures.” ‘When an item or items for temporary bridges, coffer- dams, shoring systems, or water control systems is included in the bid schedule, payment will be the lump sum bid for each such structure or system that is listed on the bid schedule and that is constructed and removed in accordance with the requirements of the contract docu- ‘ments. Such payment includes full compensation for all costs involved with the furnishing of all materials and the construction, maintenance, and removal of such tempo- rary works.SECTION 4 DRIVEN FOUNDATION PILESTable of Contents SPECIFICATIONS AND COMMENTARY 4.1 DESCRIPTION 42. MATERIALS 42.1. Steel Pies... 42.1.1 PAINTING... 42.2 Timber Pites. 4.2.3. Concrete Piles.. 4.3, MANUFACTURE OF PILES 43.1 Precast Concrete Piles... 43.1.1 FORMS.. 43.1.2 CASTING.. 43.13 FINIS! : : 43.1.4 CURING AND PROTECTION. 43.15 PRESTRESSING.. 43.1.5.1 Working Drawings... 43.1.6 STORAGE AND HANDLING 43.2 Cast-in-Place Conerete Piles 43.2.1 INSPECTION OF METAL SHELLS. 43.2.2 PLACING CONCRETE. 44- DRIVING PILES. sn 4.4.1 Pile Driving Equipment. 44.1.1 HAMMER: 44111 Gener 1.12. Drop Hammers. L4.1.13 Ain/Steam Hammers. 44.1.14 Diesel Hammers 441.15. Vibratory Hammers. L4.1.1.6 Additional Equipment or Method: 44.1.2. DRIVING APPURTENANCES. 44.2.1 Hammer Cushion 44.1.2.2 Pile Drive Head. 4.1.23 Pile Cushion. 4.41.24 Leads 44.1.2.5 Followers. 44.126 Jess. 442. Preparation for Drivin 442.1 SITE WORK. 442.1.1 Excavatior 4.42.12 Preboring to Facilitate Driving 44.2.1.3. Predrilled Holes in Embankments, 4iii4s 442.2 PREPARATION OF PILING ... 4422.2 Pointing.. 44.223 Pile Shoes and Lugs.. 443 Driving 443.1, DRIVING OF TEST PILES. 443.2 ACCURACY OF DRIVING 444 Determination of Bearing Capacity. GENERAL. : ‘METHOD A—EMPIRICAL PILE FORMULAS. METHOD B—WAVE EQUATION ANALYSIS. 44 METHOD C—DYNAMIC LOAD TESTS 4.44.5 METHOD D-—-STATIC LOAD TESTS 445 Splicing of Piles 445.1 STEEL PILI 445.2 CONCRETE PILES 4453. TIMBER PILES 44.6 Defective Piles 4.4.7 Pile Cut-Off. 447.1 GENERA\ 447.2 TIMBER PILES MEASUREMENT AND PAYMENT. 45.1 Method of Measurement... 45.11 TIMBER, STEEL, AND CONCRETE PILI 45.1.1.1 Piles Fumished, 45.1.1.2 Piles Driven, 45.1.2. PILE SPLICES, PILE SHOES, AND Pl 45.13 LOAD TESTS : 45.2 Basis of Payment ivSPECIFICATIONS COMMENTARY. SECTION 4—DRIVEN FOUNDATION PILES 4.1 DESCRIPTION This work shall consist of furnishing and driving foundation piles of the type and dimensions designated in the contract documents, including cutting off or build- ing up foundation piles when required. This specification also covers providing test piles and performing loading tests. Piling shall conform to and be installed in accor- dance with these specifications; at the location; and to the elevation, penetration, and bearing capacity shown in the contract documents or as directed by the Engineer. Except when test piles are required, the Contractor shall furnish the piles in accordance with the dimensions shown in the contract documents. When test piles are required, the pile Tengths shown in the contract docu- ‘ments are for estimating purposes only and the actual Tengths to be furnished for production piles shall be determined by the Engineer after the test piles have been driven, The lengths given in the order list provided by the Engineer shall include only the lengths anticipated for use in the completed structure, The Contractor shall increase the lengths shown or ordered to provide for fresh heading and for such additional length as may be necessary to suit the method of operation, without added ‘compensation, 42 MATERIALS 424 Steel Piles ‘The structural steel used for foundation piling shall conform to the Specification for Structural Steel for Bridges, AASHTO M 270M (ASTM A 709M) Grades 250, 345, or 345W, or to the Specification for Piling for Use in Marine Environment, ASTM A 690M. 42.1.1 PAINTING Unless otherwise provided, when steel piles or steel pile shells extend above the ground surface or water sur- face, they shall be protected by the paint system speci- fied for painting new stec! in a high-pollution or coastal environment as described in Section 13, “Painting.” This protection shall extend from an elevation 600 mm below 4AASHTO LRFD Bridge Construction Specifications ‘SPECIFICATIONS COMMENTARY 43 the water or ground surface to the top of the exposed steel. 42.2 Timber Piles ‘Timber piles shall conform to the requirements of the Specification for Wood Products, AASHTO M 168, ‘Timber piles shall be treated or untreated as indicated in the contract documents. Preservative treatment shall con- form to the requirements of Section 17, “Preservative ‘Treatment of Wood.” ‘The method of storing and handling shall be such as to avoid injury to the piles. Special care shall be taken to avoid breaking the surface of treated piles. Canthooks, dogs, or pike-poles shall not be used. Cuts or breaks in the surface of treated piling and bolt holes shall be treated as specified in Article 16.3.3, “Treated Timber.” 42.3 Conerete Piles Conerete piles shall consist of either precast concrete piles or cast-in-place concrete piles cast in steel shells. Portland cement concrete shall conform to the require- ‘ments in Section 8, “Concrete Structures,” and unless another class is shown in the contract documents, con- crete shall be Class A. Reinforcing steel shall conform to the requirements of Section 9, “Reinforcing Steel,” and prestressing shall conform to the requirements of Section 10, “Prestressing,” Steel shells for cast-in-place concrete piles shall be of not less than the thickness shown in the contract docu- ments. The Contractor shall furnish shells of greater thickness if necessary to provide sufficient strength and rigidity to permit driving with the equipment selected for use without damage, and to prevent distortion caused by soil pressures or the driving of adjacent piles. The shells shall also be watertight to exclude water during the plac- of concrete. Alternative designs for shells must be approved before any driving is done. The shells may be cylindrical, tapered, or step-tapered. 43 MANUFACTURE OF PILES 43.1 Precast Concrete Piles 43.1.1 FORMS Forms for precast concrete piles shall conform to the general requirements for concrete form work as provided in Section 3, “Temporary Works.” Forms shall provide access for vibration and consolidation of the concrete. 4243 SPECIFICATIONS 43.1.2. CASTING Handling and placing of conerete shall conform to the requirements of Section 8, “Concrete Structures,” and these specifications. Special care shall be taken to place the concrete so as to produce satisfactory bond with the reinforcement and avoid the formation of “stone pock- ts," honeycomb, or other such defects. To secure uniformity, the concrete in each pile shall be placed continuously and shall be compacted by vibrat- ing or by other means acceptable to the Engineer. The forms shall be overfilled, the surplus concrete screeded off, and the top surfaces finished to a uniform, even tex- ture similar to that produced by the forms. 43.13 FINISH Portions of piling exposed to view shall be finished in accordance with the provisions goveming the finishing of concrete columns. Other piling shall not be finished ‘except as set forth above. 43.1.4 CURING AND PROTECTION Conerete ples shall be cured as provided in Section 8, “Concrete Structures,” and in these specifications. As soon as the piles have set sufficiently to avoid damage, they shall be removed from the forms and stacked in a ccuring pile separated from each other by wood spacing blocks. No pile shall be driven until atleast 21 days after cast- ing and, in cold weather, for a longer period as deter- mined by the Engineer. Concrete piles for use in Seawater or sulfate soils shall be cured for not less than 30 days before being used. Concrete shall be protected from freezing until the compressive strength reaches at least 08 f, 43.1.5 PRESTRESSING Prestressing of concrete piles shall conform to the provisions of Section 10, “Prestressing.” 43.1.5.1 Working Drawings The Contractor shall submit two sets of working drawings for prestressed concrete piles to the Engineer at the job site. Said drawings shall show the sions, materials, prestressing methods, tendon arrange- rent, and prestressing forces proposed for use, and any addition or rearrangement of reinforcing steel from that shown in the contract documents. Construction of the 43 Section 4—Driven Foundation Piles ‘COMMENTARYAASHTO LRED Bridge Construction Specifications SPECIFICATIONS 44 COMMENTARY piles shall not begin until the drawings have been approved by the Engineer. 43.16 STORAGE AND HANDLING Removal of forms, curing, storing, transporting, and handling of precast concrete piles shall be done in such a ‘manner as to avoid excessive bending stresses, cracking, spalling, or other injurious results. Design requirements of the AASHTO LRFD Bridge Design Specifications, Article 5.13.4.1, shall apply. Piles to be used in seawater or in sulfate soils shall be handled so as to avoid surface abrasions or other injuries exposing the interior concrete, 43.2. Cast-in-Place Concrete Piles 43.2.1 INSPECTION OF METAL SHELLS At all times prior to the placing of concrete in the driven shells, the Contractor shall have available a suit- able light for the inspection of each shell throughout its centre length, 43.2.2 PLACING CONCRE No conerete shall be placed until all driving within a radius of 4600 mm of the pile has been completed, or all driving within the above limits shall be discontinued ‘until the concrete in the last pile cast has set for at least five days. Concrete for cast-in-place piles shall be dense and homogeneous. In liew of the provisions concerning vibra- tion of concrete as specified in Article 8.7.4, “Consolida- tion,” vibration or rodding of concrete for cast-in-place piles will only be required to a depth of 1500 mm below the ground surface. Concrete shall be placed for each pile in a single con- ‘tinuous operation with the flow of concrete directed down the center of the pile so as to consolidate the con- crete by impact. Accumulations of water in shells shall be removed before the concrete is placed. After the con- crete has hardened, the top surface shall be cut back to remove laitance and to expose the aggregate as specified in Article 8.8, “Construction Joints.’ 44 DRIVING PILES 44.1 Pile Driving Equipment Driving equipment that damages the piling shall not be used. 44 43.1.6 Storage and handling design requirements refer to Article 5.13.4.1, “Concrete Piles,” of the AASHTO LRFD Bridge Design Specifications, 1994,4a ‘SPECIFICATIONS Section 4—Driven Foundation Piles COMMENTARY All pile driving equipment, including the pile driving ‘hammer, hammer cushion, drive head, pile cushion, and ‘other appurtenances to be furnished by the Contractor shall be approved in advance by the Engineer before any driving can take place. Pursuant to obtaining this approval, the Contractor shall submit a description of pile driving equipment to the Engineer at least two weeks before pile driving is to begin. ‘Whenever the bearing capacity of piles is specified to be determined by Article 4.4.4.3, “Method B—Wave Equation Analysis,” the Contractor shall also submit cal- culations, based on a wave equation analysis, demon- strating that the piles can be driven with reasonable effort to the ordered lengths without damage. The following hammer efficiencies shall be used in a ‘wave equation analysis: Hammer Type Efficiency (in Percent) Single acting air/steam. or Double acting air/steam 50 Diesel n In addition to the other requirements of these speci cations, the criteria that the Engineer will use to evaluate the driving equipment consist of both the required num- ber of hammer blows per 300 mm and the pile stresses at the required ultimate pile capacity. The required number of hammer blows indicated by calculations at the required bearing capacity shall be between 36 and 120 per 300 mm for the driving equipment to be deemed acceptable, In addition, for the driving equipment to be deemed acceptable, the pile stresses, which are indicated by the calculations, to be generated by the driving equipment shall not exceed the values below: + For steel piles, compressive driving stress shall not exceed 90 percent of the yield point of the pile ‘material. + For concrete ples, tensile stresses shall not exceed 0.25 multiplied by the square root of the concrete compressive strength, fg, plus the effective pre- stress valu, ie, (0.25 ff + prestress), and com pressive stresses shall not exceed 85 percent ofthe Compressive strength minus the effective prestress value, ic. (O85 (7, ~ prestress). + For timber piles, the compressive driving. stress shall not exceed three times the allowable static design strength listed in the contract documents.‘AASHTO LRED Bridge Construction Specifications. SPECIFICATIONS These criteria will be used in evaluating calculated results to determine acceptability of the Contractor's proposed driving system, During pile driving operations, the Contractor shall uuse the approved system. Any change in the driving system will only be considered after the Contractor has ‘submitted revised pile driving equipment data and caleu- lations. The Contractor will be notified of the acceptance (or rejection of the driving system changes within 7 calen- dar days of the Engineer's receipt of the requested change. The time required for submission, review, and approval of a revised driving system shall not constitute the basis for a contract time extension to the Contractor. Approval of pile driving equipment shall not relieve the Contractor of responsibility to drive piles, free of damage, to the bearing and tip elevation shown in the contract documents. 44.1.1 HAMMERS 4 1.1 General Piles may be driven with a drop hammer, an air/steam ‘hammer, or a diesel hammer conforming to these specifi- cations. Pile driving hammers other than drop hammers shall be of the size needed to develop the energy required to drive piles at a penetration rate of not less than 2.5 mm. per blow at the required bearing value. 44.112 Drop Hammers Drop (gravity) hammers shall not be used for concrete piles or for piles whose design load capacity exceeds 267000 N, When gravity hammers are permitted, the ram shall have a mass not less than 900 kg and the height. of drop shall not exceed 4600 mm. In no case shall the ram mass of gravity hammers be less than the combined ‘mass of the drive cap and pile. All gravity hammers shall be equipped with hammer guides to ensure concentric impact on the drive head or pile cushion, 441.13 Air/Steam Hammers ‘The mass of the striking part of air/steam hammers used shall not be less than one-third the mass of pile and drive cap, and in no case shall the striking part have a ‘mass Jess than 1250 kg. The plant and equipment fur- nished for air/steam hammers shall have sufficient capacity to maintain, under working conditions, the pres- sure at the hammer specified by the Manufacturer. 4-6 COMMENTARY 4a44 SPECIFICATIONS 441.14 Diesel Hammers Open-end (single acting) diesel hammers shall be equipped with a device to permit the Engineer to deter- ‘mine hammer stroke at all times during pile driving oper- ations. Closed-end (double acting) diese! hammers shall bbe equipped with a bounce chamber pressure gauge in ‘g0od working order, mounted near ground level s0 as to be easily read by the Engineer. A correlation chart of bounce chamber pressure and delivered hammer energy shall be provided by the Contractor. 44,115 Vibratory Hammers Vibratory or other pile driving methods may be used ‘only when specified in the contract documents or in writ- ing by the Engineer. Except when pile lengths have been determined from load test piles, the bearing capacity of piles driven with vibratory hammers shall be verified by redriving the first pile driven in each group of 10 piles ‘with an impact hammer of suitable energy to measure the pile capacity before driving the remaining piles in the group. 44,1.1.6 Additional Equipment or Methods In case the required penetration is not obtained by the use of a hammer complying with the minimum require ‘ments above, the Contractor may be required to provide ‘hammer of greater energy or, when permitted, resort to supplemental methods such as jetting or preboring. 44.1.2. DRIVING APPURTENANCES 44.1.2. Hammer Cushion ‘All impact pile driving equipment except gravity hammers shall be equipped with a suitable thickness of hammer cushion material to prevent damage to the ham- mer or pile and to ensure uniform driving behavior. Hammer cushions shall be made of durable, manufac- tured materials that will retain uniform properties during, driving. Wood, wire rope, or asbestos hammer cushions shall not be used. A striker plate shall be placed on the hammer cushion to ensure uniform compression of the cushion material. The hammer cushion shall be inspected inthe presence of the Engineer when beginning pile driv- ing and after each 100 hours of pile driving, The hammer cushion shall be replaced by the Contractor before driv ing is permitted to continue whenever there is a reduction of hammer cushion thickness exceeding 25 percent of the original thickness. 47 ‘Section 4—Driven Foundation Piles COMMENTARYAASHTO LRFD Bridge Construction Specifications ‘SPECIFICATIONS 44.1.2.2 Pile Drive Head Piles driven with impact hammers shall be fitted with aan adequate drive head to distribute the hammer blow to the pile head. The drive head shall be axially aligned with the hammer and the pile, The drive head shall be ‘guided by the leads and not be free-swinging. The drive head shall fit around the pile head in such a manner as to prevent transfer of torsional forces during driving while ‘maintaining proper alignment of hammer and pile. For steel and timber piling, the pile heads shall be cut ‘squarely and a drive head provided to hold the longitudi- nal axis of the pile in line with the axis of the hammer. For precast concrete and prestressed concrete piles, the pile head shall be plane and perpendicular to the lon- gitudinal axis of the pile to prevent eccentric impacts from the drive head. For special types of piles, appropriate driving heads, mandrels, or other devices shall be provided so that the piles may be driven without damage. 4.4.12.3 Pile Cushion ‘The heads of concrete piles shall be protected by a pile cushion when the nature of the driving is such as to ‘unduly injure them. When plywood is used, the mini ‘mum thickness placed on the pile head prior to driving shall not be less than 100 mm. A new pile cushion shall be provided if, during driving, the cushion is ci pressed to less than one-half the original thickness or begins to burn, The pile cushion dimensions shall be such as to distribute the blow of the hammer throughout the cross-section of the pile. 441.24 Leads Pile driving leads that support the pile and the ham- ‘mer in proper positions throughout the driving operation shall be used. Leads shall be constructed in a manner that affords freedom of movement of the hammer while ‘maintaining alignment of the hammer and the pile to ensure concentric impact for each blow, The leads shall be of sufficient length to make the use of a follower unnecessary and shall be so designed as to permit proper alignment of battered piles. 44.125 Followers Followers shall be used only when approved in writ- ing by the Engineer or when specified in the contract documents. When a follower is permitted, in order to verify that adequate pile penetration is 48 COMMENTARY 4a44 ‘SPECIFICATIONS develop the desired pile capacity, the first pile in each bent and every tenth pile driven thereafter shall be fur nished sufficiently long and shall be driven full length without a follower. The follower and pile shall be held and maintained in equal and proper alignment during driving. The follower shall be of such material and ‘dimensions to permit the piles to be driven to the length determined to be necessary from the driving of the full- length ples. The final position and alignment of the first two piles installed with followers in each substructure unit shall be verified to be in accordance with the loca- tion tolerances specified in Article 443, “Driving,” before additional ples ae installed. 4412.6 Jets Jetting shall be permitted only if specified in the con- tract documents or approved in writing by the Engineer. When jetting is not required, but approved after the Con- {ractor’s request, the Contractor shall determine the num- ber of jets, and the volume and pressure of water at the Jet nozzles that are necessary to freely erode the material adjacent to the pile without affecting the lateral stability of the final in-place pile. The Contractor shall be respon- sible for all damage to the site caused by jetting ‘operations. When jetting is specified in the contract documents, the jetting plant shall have sufficient capacity to deliver at all times a pressure equivalent to at least 0.7 MPa at ‘wo 20-mm jet nozzles. Ineither case, unless otherwise indicated by the reer, jet pipes shall be removed when the pile tip is @ minimum of 1500 mm above prescribed tip elevation and the pile shall be driven to the required bearing capacity with an impact hammer. Also, the Contractor shall con- trol, teat if necessary, and dispose of all jet water in a ‘manner satisfactory to the Engineer. 442. Preparation for Driving 442.1 SITE WORK 4421.1 Excavation In general, piles shall not be driven until after the excavation is complete. Any material forced up between the piles shall be removed to the correct elevation before concrete for the foundation is placed. 49 Section 4—Driven Foundation Piles COMMENTARYAASHTO LRED Bridge Construction Specifications, SPECIFICATIONS 44.2.1.2 Preboring to Facilitate Driving When required by the contract documents, the Con- tractor shall prebore holes at pile locations to the depths shown in the contract documents or allowed by the Engi- neer. Prebored holes shall be smaller than the diameter or diagonal of the pile cross-section and sufficient to allow penetration of the pile to the specified depth. If subsur- face obstructions such as boulders or rock layers are encountered, the hole diameter may be increased to the least dimension that is adequate for pile installation. Any void space remaining around the pile after completion of diving shall be filled with sand or other approved mate- rial. The use of spuds shall not be permitted in lieu of preboring, unless specified in the contract documents or approved in writing by the Engineer. Material resulting from drilling holes shall be disposed of as approved by the Engineer. 442.13 Predrilled Holes in Embankments Piles to be driven through newly constructed embank- ‘ments shall be driven in holes prebored or spudded through the embankment when the depth of the new embankment is in excess of 1500 mm. The hole shall hhave a diameter of not less than the greatest dimension of the pile cross-section plus 150 mm, After driving the pile, the space around the pile shall be filled to ground surface with dry sand or pea gravel. Material resulting from drilling holes shall be disposed of as approved by the Engineer. 44.2.2 PREPARATION OF PILING In addition to squaring up pile heads prior to driving, piles shall be further prepared for driving as described below. 4422.1 Collars When timber piles are required to be driven to more than 310 000 N bearing or when driving conditions oth- cerwise require it, collars, bands, or other devices shall be provided to protect piles against splitting and brooming. 4422.2 Pointing ‘Timber piles shall be pointed where required by soil conditions. When necessary, the piles shall be shod with metal shoes of a design satisfactory to the Engineer, the s of the piles being carefully shaped to secure an ‘even and uniform bearing on the shoes. 44 COMMENTARY C4.42.1.2 ‘A spud is a short, strong driven member that is removed to make a hole for inserting a pile. =~44 SPECIFICATIONS 4422.3. Pile Shoes and Lugs Pile shoes used to protect all types of pi driving is expected and pile lugs used to increase the bearing capacity of steel piles shall be of the types shown in the contract documents and shall be used at the loca- tions specified or ordered by the Engineer. Steel pile shoes shall be fabricated from cast steel conforming to ‘AASHTO M 103M (ASTM A 27M). Such pile shoes or lugs used at the option of the Con- tractor shall be of a type approved by the Engineer. 443° Driving Piles shall be driven to the minimum tip elevations and bearing capacity shown in the contract documents or approved by the Engineer. Piles that heave more than 5 ‘mm upward during the driving of adjacent piles shall be redriven. 443.1 DRIVING OF TEST PILES ‘When shown in the contract documents, test piles and piles for static oad tests shall be furnished to the lengths ordered and driven at the locations and to the elevations directed by the Engineer before other piles in the area represented by the test are ordered or driven. All test piles shall be driven with impact hammers unless specifi- cally stated otherwise in the contract documents. In gen- eral, the ordered length of test piles will be greater than the estimated length of production piles in order to pro- vide for variation in soil conditions. The driving equip- ment used for driving test piles shall be identical to that which the Contractor proposes to use on the production piling. Approval of driving equipment shall conform with the requirements of these Specifications. Unless otherwise permitted by the Engineer, the Contractor shall excavate the ground at each test pile to the elevation of the bottom of the footing before the pile is driven. Test piles shall be driven to a hammer blow count established by the Engincer at the estimated tip eleva- tion. Test piles that do not attain the hammer blow count specified above at a depth of 300 mm above the esti- mated tip elevation shown in the contract documents shall be allowed to “set up” for a period of from 12 to 24 hhours, as determined by the Engineer, before being redriven. When possible, the hammer shall be warmed up before redriving begins by applying at least 20 blows to another pile. Ifthe specified hammer blow count is not attained on redriving, the Engineer may direct the Con- tractor to drive a portion or al of the remaining test pile length and repeat the setup-redrive procedure. When ordered by the Engineer, test piles driven to plan grade Section 4—Driven Foundation Piles COMMENTARYAASHTO LRED Bridge Construction Specifications SPECIFICATIONS and not having the hammer blow count required shall be spliced and driven until the required bearing is obtained, 4.4.3.2 ACCURACY OF DRIVING Piles shall be driven with a variation of not more than 1:50 from the vertical or from the batter shown in the contract documents, except that piles for trestle bents shall be driven so that the cap may be placed in its proper location without adversely affecting the resistance of the piles. Foundation piles shall not be out of the position shown in the contract documents by the greater of 25 percent of their diameter or 150 mm after driving, Any increase in footing dimensions or reinforcing caused by ‘out-of-position piles shall be at the Contractor's expense. 44.4 Determination of Bearing Capacity 44.4.1 GENERAL Piles shall be driven to the bearing capacity shown in the contract documents, The bearing capacity of piles will be determined by the Engineer as provided in the contract documents using one or a combination of the following methods. Method A, Empirical Pile Formula, will be used unless otherwise specified in the contract, documents. 4.4.42 METHOD A—EMPIRICAL PILE FORMULAS When not driven to practical refusal, the factored bearing resistance of piles may be determined by an empirical pile formula. Unless otherwise provided in the contract documents, the following formulas (Engineer- ing News-Record) may be used. For drop (gravity) hammers: (0.48)10 WH », - Oe (4442-1) For all other hammers: (4442-2) where: P, = unfactored, ic., nominal, bearing capacity, N W = mass of striking parts of the hammer, kg HE = height of fall in mm 44 COMMENTARY 4.4.42 ‘The Engineering News-Record formula has been ‘modified for use with factored loads by multiplying by the sum of the factored loads and dividing by the sum of the unfactored loads. This is not a statistically calibrated adjustment and, therefore, does not represent any improvement in the well-known inaccuracy of the Engi- neering News-Record equation. The resistance factor for use with the Engineering News-Record (ENR) equations is dependent on the method used to determine the geo- technical resistance of the axially loaded pile. The factor of 0.80 is a further reduction applicable only when the ENR formula is applied. ‘The factor 10 in Equation 1 is the gravitational accel- ‘ration rounded to an even number. The factor 0.48 in Equations 1 and 2 is the product, 0.6 x 0.8. The 0.8 is a temporary measure as this reduc- tion is expected to be included as part of the resistance factor starting with the 1997 Interims. The factor 0.6 is intended to account for the traditional difference between the assumed safety margin in design and that traditionally provided in Division I of the Standard Specifications.44 SPECIFICATIONS Section 4—Driven Foundation Piles COMMENTARY E = energy produced by the hammer per blow in joules, J. Value based on actual hammer stroke or bounce chamber pressure ‘observed (double acting diesel hammer) average penetration in mm per blow for the last 5 to 10 blows for gravity hammers and the last 10 to 20 blows for all other hammers. ‘The above formulas are applicable only when: the hammer has a free fall (gravity and single- acting hammers only), the head of the pile is not broomed, crushed, or otherwise damaged, the penetration is reasonably quick and uniform, there is no appreciable rebound of the hammer, and a follower is not used. ‘The penetration per blow may be measured either dur- ing intial driving or by redriving with a warm hammer ‘operated at full energy after a pile set period, as deter- mined by the Engineer. If water jets are used in connection with the driving, the bearing capacity shall be determined by the formulas, above from the results of driving after the jets have been withdrawn, 4.4.43 METHOD B—WAVE EQUATION ANALYSIS ‘When specified in the contract documents, ultimate bearing capacity of a pile shall be determined by using a ‘wave equation analysis. Soil, pile, and driving equipment properties to be used in this analysis shall be as shown in the contract documents or as determined by the Engineer using data obtained from the Contractor, test borings, and, when used, dynamic pile tests (Method C). ‘The unfactored (i.e., nominal) bearing resistance of a pile shall be taken as 85 percent of the caleulated ulti ‘mate bearing capacity as determined from a wave equa- tion analysis alone for a given rate of penetration. When the ultimate bearing capacity is determined from a wave equation analysis that has been calibrated to the results of a dynamic pile test, the unfactored, ic., nominal, resis- tance shall be taken as the calculated ultimate bearing capacity from wave equation analysis for a given rate of penetration, 4.13 44.43, ‘The 85 percent factor is expected to be included in the AASHTO LRED Bridge Design Specifications in 1997.AASHTO LRFD Bridge Construction Specifications ‘SPECIFICATIONS 44.44 METHOD C—DYNAMIC LOAD TESTS Dynamic measurements shall be taken by the Engi- neer during the driving of piles designated as dynamic load test piles. The ultimate capacity of the pile will be determined withthe use of ile analyzer instruments, and this shall be taken as the nominal resistance. Prior to placement in the leads, the Contractor shall ‘make each designated concrete and/or timber pile avail able for taking wave speed measurements and shall pre- drill the required instrument attachment holes. Predriving wave speed measurements will not be required for stel piles. When wave speed measurements aze made, the pling shall be supported off the ground in ‘horizontal position and not in contact with other piling. ‘The Engineer shall furnish the equipment, materials, and labor necessary for diling holes in the piles for mount- ing the instruments. ‘The Contractor shall either attach the instruments to the pile after the pile is placed in the leads or provide the Engineer with reasonable means of access to the pile for attaching instruments after the pile is placed in the leads. ‘A platform with @ minimum size of 1200 x 1200 mm (1.44 m2) designed to be raised to the top of the pile White the pile is located in the leads, shall be provided by the Contractor. ‘The Contractor shall furnish electric power for the dynamic test equipment. The power supply atthe outlet shall be 10 ampere, 115 volt, 5-60 cycle, alternating current (AC) only. Field generators used as the power source shall be equipped with functioning meters for ‘monitoring voltage and frequency levels. ‘The Contractor shall furnish a shelter to protect the dynamic test equipment from the elements. The shelter shall have a minimum floor size of 2400 > 2400 mm 6.76 m2) and minimum roof height of 2100 mm. The inside temperature of the shelter shall be maintained above 7°C. The shelter shall be located within 15 000 mm of the test location, The Contractor shall drive the pile to the depth at which the dynamic test equipment indicates that the design bearing capacity shown in the contract documents has been achieved, unless directed otherwise by the Engineer. If directed by the Engineer, the Contractor shall reduce the driving energy transmitted to the pile by using additional cushions or reducing the energy output of the hammer in order to maintain acceptable stresses in the piles. If non-axial driving is indicated by dynamic test equipment measurements, the Contractor shall immediately realign the driving system, ‘When directed by the Engineer, the Contractor shall wait up to 24 hours and, after the instruments are reat- tached, redrive the dynamic load test pile. The hammer COMMENTARY 4444 SPECIFICATIONS shal be warmed up before redrive begins by applying at least 20 blows to another pile. The maximum amount of penetration required during redrive shall be 150 mm or the maximum total number of hammer blows required will be 50, whichever occurs first. After redriving, the Engineer shall either provide the cut-off elevation or specify additional pile penetration and testing. 4445 METHOD D—STATIC LOAD STS Load tests shall be performed by procedures set forth in ASTM D 1143 using the quick load compression test method, except that the test shall be taken to plunging failure or three times design load. Testing equipment and ‘measuring systems shall conform to ASTM D 1143. The Contractor shall submit detailed contract documents of the proposed loading apparatus, prepared by a licensed professional engineer, to the Engineer for approval. The apparatus shall be constructed to allow the various incre- ments ofthe load to be placed gradually without causing vibration to the test pile. When the approved method requires the use of tension (anchor) piles that will later be used as permanent piles in the work, such tension piles shall be of the same type and diameter as the production piles and shall be driven in the location of permanent piles when feasible. ‘The nominal resistance shall be taken as the failure load. ‘The failure load of a pile tested under axial compres- sive load is that load which produces a settlement at fail ure ofthe pile head equal to: Sp S+8+0008D) — (4.4.45-1) settlement at failure in mm. pile diameter or width in mm = elastic deformation of total unsupported pile length in mm The top elevation of the test pile shall be determined immediately after driving and again just before load test- ing to check for heave. Any pile that heaves more than 3 ‘mm shall be redriven or jacked to the original elevation prior to testing. Unless otherwise specified in the con- tract documents, a minimum three-day waiting period shall be observed between the driving of any anchor piles or the load test pile and the commencement of the load test. Section 4—Driven Foundation Piles COMMENTARYAASHTO LRED Bridge Construction Specifications SPECIFICATIONS 44S Splicing of Piles 44.5.1 STEEL PILES Full-length piles shall be used where practicable. If splicing is permitted, the method of splicing shall be as specified in the contract documents or as approved by the Engineer. The are method of welding shall be preferred when splicing steel piles. Welding shall be performed only by certified welders. 44.5.2 CONCRETE PILES Concrete piles shall not be spliced, other than to pro- duce short extensions as permitted herein, unless speci- fied in the contract documents or in writing by the Engineer. Short extensions or “build-ups” may be added to the tops of reinforced concrete ples to correct for unantici- pated events. After the driving is completed, the concrete atthe end ofthe pile shall be cut away, leaving the rein- forcing steel exposed for a length of 40 diameters. The final cut ofthe concrete shall be perpendicular to the axis of the pile. Reinforcement similar to that used in the pile shall be securely fastened tothe projecting steel and the necessary form work shall be placed, care being taken to prevent leakage along the pile. The concrete shal be of| not less than the quality used in the pile. Just prior to placing concrete, the top of the pile shall be thoroughly flushed with water, allowed to dry, then covered with 2 thin coating of neat cement, mortar, ot other suitable bonding material. The forms shall remain in place not less than seven days and shall then be carefully removed and the entire exposed surface ofthe pile finished as pre- viously specified. 4.4.53. TIMBER PILES ‘Timber piles shall not be spliced unless specified in the contract documents or in writing by the Engineer. 4.4.6 Defective Piles “The procedure incident tothe driving of ples shall not subject them to excessive and undue abuse producing crushing and spalling ofthe concrete, injurious splitting, splintering and brooming of the wood, or excessive deformation of the stcel. Manipulation of ples to force them into proper position, considered by the Engineer to be excessive, will not be permitted. Any pile damaged by reason of intemal defects, by improper driving, driven ‘ut of its proper location, or driven below the butt eleva: tion fixed by the contract documents or by the Engineer COMMENTARY 4444 SPECIFICATIONS shall be corrected at the Contractor's expense by one of the following methods approved by the Engineer for the pile in question: ‘+ The pile shall be withdrawn and replaced by a new and, if necessary, longer pile. ‘A second pile shall be driven adjacent to the defec- tive or low pile. ‘The pile shall be spliced or built up as otherwise provided herein or a sufficient portion of the foot ing extended to properly embed the pile. All piles pushed up by the driving of adjacent piles or by any other cause shall be driven down again. ‘All such remedial materials and work shall be fur- nished at the Contractor's expense. 44,7 Pile Cut-Off 447.1 GENERAL Al piles shall be cut off to a true plane at the eleva- tions required and anchored to the structure as shown in the contract documents. All cut-off lengths of pling shall remain the property of the Contractor and shall be properly disposed of, 44.7.2. TIMBER PILES ‘Timber piles that support timber caps or grillage shall be sawn to conform to the plane of the bottom of the superimposed structure. The length of pile above the ele- vation of cut-off shall be sufficient to permit the com- plete removal ofall material injured by driving, but piles driven to very nearly the cutoff elevation shall be care- fully added or otherwise freed from all broomed, splin- tered, or otherwise injured material. Immediately after making final cut-off on treated tim- ber foundation piles, the cut area shall be given two lib- eral applications of preservative followed by a heavy application of coal-tar roofing cement or other approved sealer. Treated timber piles that will have the cutoff exposed in the structure shall have the cut area treated with three coats of a compatible preservative material ‘meeting the requirements of American Wood Preservers ‘Association Standard M4. A minimum time period of 2 hours shall elapse between each application, Section 4—Driven Foundation Piles COMMENTARY C4a72 ‘Timber pile preservatives refers to the American ‘Wood Preservers Association Standard M4, 1992.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS 45 MEASUREMENT AND PAYMENT 45.1 Method of Measurement 4.5.1.1 TIMBER, STEEL, AND CONCRETE PILES 45.1.1.1 Piles Furnished ‘The quantities of each type of pile to be paid for shall be the sum of the lengths in meters of the piles. The piles shall be of the types and lengths indicated in the contract documents or ordered in writing by the Engineer, fur- nished in compliance with the material requirements of these specifications and stockpiled or, in the case of driven cast-in-place concrete ples, installed in good con- dition at the site of the work by the Contractor, and accepted by the Engineer. The length of piles, including test piles, furnished by the Contractor to replace piles that were previously accepted by the Engineer but were subsequently damaged prior to completion of the con- tract documents, shall not be included. ‘When extensions of piles are necessary, the extension length ordered in writing by the Engineer shall be included in the total length of piling furnished. 45.112 Piles Driven ‘The quantities of driven piles of each type to be paid for shall be the number of acceptable piles of each type that were driven, Preboring, jetting, or other methods used for facilitat- ing pile driving procedures when either required or per- ‘mitted shall not be measured, and payment shall be considered included in the unit price paid for the piles driven. 45.12 PILE SPLICES, PILE SHOES, AND PILE LuGs When pile splices, protective pile tip shoes, of soil shear lugs are shown in the contract documents, the num- ber of pile splices, shoes, or lugs measured for payment shall be those shown in the contract documents, or ordered in writing by the Engineer, and actually installed (on piles used in the work. No payment shall be made for splices, shoes, or lugs used at the option of the Contrac- tor. When not shown in the contract documents, pile splices, shoes, or lugs ordered by the Engineer shall be paid for as extra work. COMMENTARY 4545 SPECIFICATIONS Section 4—Driven Foundation Piles 45.13 LOAD TESTS ‘The quantity of load tests to be paid for shall be the ‘number of load tests completed and accepted, except that load tests made at the option of the Contractor shall not be included in the quantity measured for payment, ‘Anchor and test piles for load tests, whether incorpo- rated into the permanent structure or not, shall be mea- sured as provided for piles furnished and piles driven and shall be paid for under the appropriate pay item. 45.2 Basis of Payment ‘The quantities, determined as provided, shall be paid for at the contract documents price per unit of measure- ‘ment, respectively, for each of the general pay items listed below, for each size and type of pile shown in the contract documents. Pay Item Pay Unit les, Furnished Meter Piles, Driven Bach Test Piles, Furnished Meter ‘Test Piles, Driven Bach Pile Load Test (Static) Each Pile Load Test (Dynamic) Each Splices Each Pile Shoes Each Pile Lugs Each Payment for furnishing piles includes full compensa- tion for all costs involved in the furnishing and delivery of all piles, including steel shells for cast-in-place driven les, to the project site and all costs involved in the fur- nishing and placing of concrete and reinforcing steel for cast-in-place concrete piles. Payment for driving piles includes full compensation for all costs involved in the actual driving and cutting off of piles and pile shells, and for all costs for which com- pens: not provided for under other pay items involved with the furnishing of labor, equipment, and materials used to construct the piles as shown in the con- tract documents. When mobilization of plant and equip- ment for the project is not paid for separately, payment for driving piles also includes full compensation for the cost of mobilization of all equipment needed for the han- dling and driving of piles after the piles have been deliv- cred to the project site, Payment for load tests includes full compensation for providing labor, equipment, and materials needed to per- form the load tests as specified.‘AASHTO LRED Bridge Construction Specifications SPECIFICATIONS COMMENTARY 4s Payment under the appropriate pay items for pile splices, shoes, and lugs includes full compensation forall costs involved with furnishing all materials and perform- ing the work involved with attaching or installing splices, shoes, or lugs to the piles, 4-20SECTION 5 DRILLED PILES AND SHAFTSSA 52 54 35 56 Table of Contents SPECIFICATIONS AND COMMENTARY DESCRIPTION WORKING DRAWINGS. MATERIALS. CONSTRUCTION. 5.41 Protection of Existing Structures, 34.2 Construction Sequence. 54.3 General Methods and Equipment.. S44 Dry Construction Method SAS Wet Construction Method . . 546 ‘Temporary Casing Construction Method... $4.7 Permanent Casing Construction Method. 548 Alternative Construction Methods 349 Excavations 5.4.10 Casings SAL Slurry. 54.12 Excavation Inspection... = $4.13 Reinforcing Steel Cage Construction and Placement $4.14 Concrete Placement, Curing, and Protection SA.15 Test Shafts and Bells. 5.4.16 Construction Tolerances.. 54.17 Integrity Testing . DRILLED SHAFT LOAD TESTS.. MEASUREMENT AND PAYMENT 5.6.1 Measurement... 5.6.1.1 DRILLED SHAFT. 5.6.1.2 BELL FOOTINGS. 5.6.1.3 TEST SHAFTS 5.6.1.4 ‘TEST BELLS. 5.6.1.5 EXPLORATION .. 5.6.1.6 PERMANENT CASING. 56.1.7 LOAD TESTS..... Sill5.6.2 Payment. 5.6.2.1 5.6.2.2 5.6.23 5.6.2.4 56.2.5 DRILLED SHAFT. BELL FOOTINGS . ‘TEST SHAFTS. ‘TEST BELLS .. EXPLORATION HOLES .. PERMANENT CASING. LOAD TESTS s.ivSPECIFICATIONS COMMENTARY SECTION 5—DRILLED PILES AND SHAFTS 5.1 DESCRIPTION ‘This work shall consist of constructing drilled founda- tion piles and shafts, with or without bell footings, including the placing of reinforcing steel and concrete, all in accordance with the contract documents and these specifications. 52 WORKING DRAWINGS When required by the contract documents, at least four weeks before work on shafts is to begin, the Con- tractor shall submit an installation plan for the construc- tion of drilled shafts to the Engineer for review and approval. The submittal shall include the following: + List of proposed equipment to be used, including cranes, drills, augers, bailing buckets, final clean: ing equipment, desanding equipment, slurry pumps, sampling equipment, tremies or concrete pumps, casings, etc, + Details of overall construction operation sequence and the sequence of shaft construction in bents or groups. + Details of shaft excavation methods. + When slurry is required, details of the method pro- posed to mix, circulate, and desand slurry. ‘+ Details of methods to clean the shaft excavation. + Details of reinforcement placement, including sup- port and centralization methods. + Details of concrete placement, and protection. curing, + Details of any required load tests. + Other information shown in the contract docu- ments or requested by the Engineer. ‘The Contractor shall not start the construction of Grilled shafts for which working drawings are required ‘until such drawings have been approved by the Engineer. st CS ‘The term “shafts,” as used in this Section, means either piles or shafts.AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS ‘Such approval will not relieve the Contractor of respon- sibility for results obtained by use of these drawings or any of the Contractor's other responsibilities under the contract documents. 53 MATERIALS S31 Concrete Concrete shall conform to the requirements of Section 8, “Concrete Structures.” The concrete shall be Class A. unless otherwise specified in the contract documents, 53.2 Reinforcing Steel Reinforcing stee! shall conform to the requirements of Section 9, “Reinforcing Steel.” 333. Casings Casings that are required to be incorporated as part of the permanent work shall conform to the requirements of Section 11, “Steel Structures.” Steel shall be AASHTO M 270M (ASTM A 709M) Grade 250 unless otherwise specified in the contract documents. SA CONSTRUCTION 5.4.1 Protection of Existing Structures All reasonable precautions shall be taken to prevent ‘damage to existing structures and utilities. These mea- sures shall include, but are not limited to, selecting con- struction methods and procedures that will prevent excessive caving of the shaft excavation and monitoring and controlling the vibrations from the driving of casing or sheeting, drilling of the shaft, or from blasting, if permitted. 542 Construction Sequence AAll excavation of the foundation in which drilled shafts are to be constructed shall be complete before shaft construction begins. Unless shown otherwise in the contract documents, where drilled shafts are to be installed in conjunction with embankment placement, they shall be constructed after the placement ofthe fill. 5-2 COMMENTARY 535a SPECIFICATIONS Section 5~Drilled Piles and Shafts COMMENTARY 5.4.3 General Methods and Equipment Excavations required for shafts and bell footings shall be performed through whatever materials are encoun- tered, to the dimensions and elevations in the contract, documents or ordered by the Engineer. The methods and equipment used shall be suitable forthe intended purpose and materials encountered. Generally, either the dry method, wet method, temporary casing method, or per- ‘manent casing method may be used as necessary to pro- duce sound, durable concrete foundation shafts free of defects. The permanent casing method shall be used only when required by the contract documents or authorized by the Engineer. When a particular method of construc- tion is required in the contract documents, that method shall be used. If no particular method is specified for use, the Contractor shall select and use the method that is needed to properly accomplish the work, as determined by site conditions and subject to approval of the Engi- eer. 544 Dry Construction Method ‘The dry construction method shall be used only at sites where the groundwater table and site conditions are suitable to permit construction of the shaft in a relatively dry excavation, and where the sides and bottom of the shaft are stable and may be visually inspected prior to placing the concrete, 345 Wet Construction Method The wet construction method shall be used at sites where a dry excavation cannot be maintained for place- ment of the shaft concrete. Unless it is demonstrated to the satisfaction of the Engineer that the surface casing is not required, tempo- rary surface casings shall be provided (o aid shaft align- ment and position, and to prevent sloughing of the top of the shaft excavation. 5-3 c34d ‘The dry method consists of drilling the shaft excava- tion, removing accumulated water and loose material from the excavation, and placing the shaf: concrete in a relatively dry excavation. CSAS Wet construction methods consist of using water or ‘mineral slurry to maintain stability of the hole perimeter while advancing the excavation to final depth, placing the reinforcing cage and shaft concrete. ‘This procedure may require desanding and cleaning the slurry; final cleaning of the excavation by means of a bailing bucket, air lift, submersible pumper, or other devices; and placing the shaft concrete with a tremie or concrete pump.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS 54.6 Temporary Casing Construction Method ‘The temporary casing construction method shall be used at all sites where the dry or wet construction meth- ‘ods are inappropriate ‘As an alternative to use of the wet excavation method, temporary casing may be installed by driving or vibra- tory procedures in advance of excavation to the lower limits of the caving material Before the casing is withdrawn and while the casing is being withdrawn, the level of fresh concrete in the casing shall be such that all the fluid trapped behind the casing is displaced upward without contaminating the shaft concrete, 5.4.7 Permanent Casing Construction Method ‘The permanent casing construction method shall be used when required by the contract documents. If full penetration cannot be attained, the Engineer may require either excavation of material within the embedded por- tion of the casing or excavation of a pilot hole ahead of the casing until the casing reaches the desired penetra- tion, In some cases, overreaming to the outside diameter of the casing may be required in order to advance the casing. ‘The casing shall be continuous between the elevations shown in the contract documents. Temporary casing in lieu of or in addition to the permanent casing shall not be used, except when specified in the contract documents or authorized in writing by the Engineer. ‘After the installation of the casing and the excavation of the shaft is complete, the casing shall be cut off at the prescribed elevation and the reinforcing steel and shaft concrete placed within the portion of the casing left in place. 5.48 Alternative Construction Methods The Contractor may propose alternative methods to prevent caving and to control ground water. Such pro- posals, accompanied by supporting technical data, shall be submitted in accordance with Article 5.2, “Working Drawings.” 54,9 Excavations If the Engineer determines that the foundation mate- rial encountered during excavation is unsuitable or dif- fers from that anticipated in the design of the drilled shaft, the bottom elevation of the drilled shaft shown in the contract documents may be adjusted during construction. 34 54 COMMENTARY C546 ‘Temporary casing construction method consists of advancing the excavation through caving material by the ‘Wet method as described in Article 5.4.5, “Wet Construc: tion Method.” When a nearly impervious formation is reached, a casing is placed in the hole and sealed in the nearly impervious formation. After the drilling fluid is removed from the casing, drilling may proceed as with the dry method except that the casing is withdrawn when the shaft concrete is placed. If seepage conditions prevent use of the dry method, excavation is completed using the wet method. Slurry may be omitted if the casing can be installed with only minor caving of the hole. C347 Permanent casing construction method consists of driving or drilling a casing to a prescribed depth before ‘excavation begins.54 SPECIFICATIONS ‘The Contractor shall take soil samples or rock cores when shown in the contract documents or as directed by the Engineer to determine the character of the material directly below the shaft excavation, The Engineer will inspect the samples or cores and determine the final depth of requited shaft excavation, Excavated materials that are removed from the shaft excavation and any drilled fluids used shall be disposed of in accordance with contract documents or as directed by the Engineer. When bell footings are shown in the contract docu- ‘ments, they shall be excavated to form a bearing area of, the size and shape shown. The bell shall be excavated by ‘mechanical methods. 5.4.10 Casings Casings shall be metal, smooth, clean, watertight, and of ample strength to withstand both handling and driving stresses and the pressure of both concrete and the sur- rounding earth materials. The outside diameter of casing shall not be less than the specified size of the shaft ‘Temporary casings shall be removed while the con- crete remains workable. Generally, the removal of tem- porary casing shall not be started until concrete placement in the shaft is at or above ground surface. Movement of the casing by rotating, exerting downward pressure, and tapping to facilitate extraction or extraction with a vibratory hammer shall be permitted. Casing extraction shall be at a slow, uniform rate with the pull in Tine with the shaft axis. A sufficient head of concrete shall be maintained above the bottom of the casing to overcome the hydro- static pressure of water or drilling fluid outside of the ceasing. S411 Slurry Slurry used in the drilling process shall be a mineral slurry. The slurry shall have both a mineral grain size that will remain in suspension and sufficient viscosi and gel characteristics to transport excavated material to a suitable screening system. The percentage and specific gravity of the material used to make the suspension shall be sufficient to maintain the stability of the excavation and to allow proper concrete placement. The level of the slurry shall be maintained at a height sufficient to pre- vent caving of the hole. ‘The mineral slurry shall be premixed thoroughly with clean fresh water, and adequate time shall be allotted for hydration prior to introduction into the shaft excavation. ‘Adequate slurry tanks shall be required when specified. No excavated slurry pits shall be allowed when slurry 5-5 Section $—Drilled Piles and Shafts COMMENTARYAASHTO LRED Bridge Construction Specifications SPECIFICATIONS tanks are required on the project without written permis- sion of the Engineer. Adequate desanding equipment will be required when specified in the contract docu- ments. Steps shall be taken as necessary to prevent the slurry from “setting up” in the shaft excavation, such as tation, circulation, and adjusting the properties of the sluny. Control tests using suitable apparatus shall be casied out by the Contractor on the mineral slurry to determine density viscosity, and pH. An acceptable range of values for those physical properties is shown in Table 5.4.1 1-1 ‘Table 54.11-1 Range of Values (at 20°C) actime | AtTimeet ofsiory | Goncreting Property Vals) | Inraducton | “inHle)” | Text Method easy gin’) [1050%01107 | 103001202 | Deny Baas Vieosty [3008 sow Mask Cone econ) i tol on PH pape or ‘The following criteria apply to Table 5.4.1 1-1 + Density shall be increased by 32 ke/m? in saltwater. + If desanding is required, sand content shall not exceed 4 percent (by volume) at any point in the shaft excavation, as determined by the American Petroleum Institute sand content test. Tests to determine density, viscosity, and pH values shall be done during the shaft excavation to establish a consistent working pattern. Prior to placing shaft concrete, slury samples shall be taken from the bottom and at intervals not exceeding 3000 mm for the full height of slurry. Any heavily con- taminated slurry that has accumulated at the bottom of the shaft shall be eliminated. The mineral slurry shall be within specification requirements immediately before shaft conerete placement. 54.12 Excavation Inspection ‘The Contractor shall provide equipment for checking the dimensions and alignment of each shaft excavation, The dimensions and alignment shall be determined by the Contractor under the direction of the Engineer. Final shaft depth shall be measured after final cleaning, ‘The shaft excavation shall be cleaned so that a mini ‘mum of 50 percent of the base shall have less than 5-6 COMMENTARY 5454 SPECIFICATIONS Section |—Drilled Piles and Shafts COMMENTARY 10 mm of sediment and at no place on the base more than 40 mm of sediment. Shaft cleanliness shall be deter- mined by the Engineer. 5.4.13 Reinforcing Steel Cage Construction and Placement The reinforcing steel cage, consisting of the steel shown in the contract documents, plus cage stiffener bars, spacers, centralizers, and other necessary appurte- nances, shall be completely assembled and placed as a unit immediately after the shaft excavation is inspected and accepted and prior to shaft concrete placement. ‘The reinforcing steel in the shaft shall be tied and sup- ported so that the reinforcing steel will remain within allowable tolerances of its intended position until the concrete will support the reinforcing steel. When con- crete is placed by tremie methods, temporary hold-down devices shall be used to prevent uplifting of the steel cage during concrete placement. Concrete spacers or other approved noncorrosive spacing devices shall be used at sulficient intervals not exceeding 1500 mm along the shaft to ensure concentric location of the cage within the shaft excavation. When the size of the longitudinal rein- forcing steel is larger than a No. 25 bar, such spacing shall not exceed 3000 mm, 5.4.14 Concrete Placement, Curing, and Protection Concrete shall be placed as soon as possible after reinforcing steel cage placement. Concrete placement shall be continuous in the shaft to the top elevation of the shafi, Placement shall continue after the shat is full until ‘good-quality concrete is evident at the top of the shaft Concrete to be placed in water or slurry shall be placed through a tremie or concrete pump using methods speci- fied in Article 8.7.5, “Underwater Placement.” Concrete to be placed in dry shafts shall be placed and consolidated as specified in Article 4.3.2, “Cast-in-Place Concrete Piles,” and these specifications. For shafts less than 2400 mm in diameter, the elapsed time from the beginning of concrete placement in the shaft to the completion of placement shall not exceed 2 hours. For shafts 2400 mm and greater in diameter, the ‘concrete placing rate shall be not less than 9000 mim of shaft height per each 2-hour period. The concrete mix shall be of such design thatthe concrete remains in work= able plastic state throughout the 2-hour placement limit. ‘When the top of shaft elevation is above ground, the portion of the shaft above ground shall be formed with a removable form or permanent casing when specified in the contract documents. 5-7 DT 1999AASHTO LRED Bridge Construction Specifications SPECIFICATIONS ‘The shaft concrete shall be vibrated or rodded to a depth of 1500 mm below the ground surface except ‘where soft uncased soil or slurry remaining in the exca- vation will possibly mix with the concrete. ‘After placement, the temporarily exposed surfaces of the shafi concrete shall be cured in accordance with the provisions in Article 8.11, “Curing Concrete.” No construction operations that would cause soil ‘movement adjacent to the shaft, other than mild vibra- tion, shall be conducted for at least 48 hours after shaft ‘concrete has been placed. Portions of drilled shafts exposed to a body of water shall be protected from the action of water by leaving the forms in place for a minimum of seven days after con- crete placement. 54.15 Test Shafts and Bells ‘Test shafts shall be constructed when required in the contract documents. The construction of test shafts will be used to determine if the methods, equipment, and pro- cedures used by the Contractor are sufficient to produce a shaft excavation that meets the requirements of the con- tract documents, ‘The Contractor shall revise the methods and ‘equipment as necessary at any time during the construc- tion of the test shaft hole to satisfactorily complete the excavation. The location of the test shaft shall be as shown in the contract documents or as directed by the Engineer. The diameter and depth of the test shaft hole or holes shall be the same as that of the production drilled shafis shown in the contract documents or directed by the Engineer, The test shaft holes shall be filled with plain concrete in the same manner that production shafts will be constructed unless a different backfill material is shown in the con- tract documents or specified by the Engineer. When the Contractor fails to satisfactorily demon- strate the adequacy of the methods, procedures, or equip- ‘ment, additional test shafts shall be provided at no cost to the Owner. ‘When shown in the contract documents or when ordered in writing by the Engineer, the reaming of bells, at specified test shaft holes will be required to establish the feasibility of belling in a specific soil stratum. 5.4.16 Construction Tolerances ‘The following construction tolerances shall be main- tained in constructing drilled shafts: 5-8 COMMENTARY 34sa SPECIFICATIONS + The drilled shaft shall be within 75 mm of the plan position in the horizontal plane at the plan eleva- tion for the top of the shat. + ‘The vertical alignment ofthe shaft excavation shall not vary from the plan alignment by more than 20 mm per meter of depth. ‘+ After all the shaft concrete is placed, the top of the reinforcing steel cage shall be no more than 150mm above and no more than 75 mm below plan position. ‘+ When casing is used, its outside diameter shall be not less than the shaft diameter shown in the con- ‘tract documents. When casing is not used, the min- imum diameter of the drilled shaft shall be the diameter shown in the contract documents for diameters 610 mm or less, and not more than ‘25 mm less than the diameter shown in the contract documents for diameters greater than 610 mm, + The bearing area of bells shall be excavated to the plan bearing area as a minimum. All other plan dimensions shown for the bells may be varied, ‘when approved, to accommodate the equipment used. ‘+ The top elevation of the shaft shall be within 25 mm of the plan top of shaft elevation. + The bottom of the shaft excavation shall be normal to the axis of the shaft within 60 mm/m of shaft diameter. Drilled shaft excavations constructed in such a man- ner that the concrete shaft cannot be completed within the required tolerances are unacceptable. Correction ‘methods shall be submitted by the Contractor for the Engineer's approval. Approval will be obtained before continuing with the drilled shaft construction. Materials and work necessary to effect correction for out-of-tolerance drilled shaft excavations shall be fur- nished at no cost to the Owner. SA.17 Integrity Testing ‘When shaft concrete is placed by the wet construction ‘method, and when called for in the contract documents, the completed shaft will be subjected to nondestructive testing to determine the extent of any defects that may be present in the shaft. Section 5—Drilled Piles and Shafts ‘COMMENTARYAASHTO LRED Bridge Construction Specifications SPECIFICATIONS ‘Work and materials required for testing that are to be furnished by the Contractor shall be as specified in the contract documents, In the event that testing discloses voids or discontinu- ities in the concrete that indicate that the drilled shaft is not structurally adequate as determined by the Engineer, the shaft shall be rejected and construction of additional Grilled shafts shall be suspended until the Contractor repairs, replaces, or supplements the defective work and the Engineer approves the remedial work. Suspension of drilled shaft construction shall remain in effect until wr ten changes to the methods of drilled shaft construction are approved by the Engineer. 5.5 DRILLED SHAFT LOAD TESTS ‘When the contract documents include load testing, all tests shall be completed before construction of any pro- duction drilled shafts. The Contractor shall allow two weeks after the last load test for the analysis of the load test data by the Engineer before specified drilled shalt tip elevations will be provided for production shafts. ‘The locations of load test shafts and reaction shafts, the maximum loads to be applied, the test equipment to be furnished by the Contractor, and the actual perfor- ‘mance of the load testing shall be as shown in the con- ‘tract documents, After testing is completed, the test shafts and any reaction shafts, if not also to be used as production shafts, shall be cut off at an elevation 900 mm below the finished ground surface. The portion of the shafts cut off shall be disposed of by the Contractor. 5.6 MEASUREMENT AND PAYMENT 5.6.1 Measurement 5.6.1.1 DRILLED SHAFT Drilled shafts, complete in place, will be measured by the meter foreach size of shaft listed in the contract doc- uments. Measurement will be along the centerline of the shaft based on the tip and shat cut-off elevations shown in the contract documents or ordered by the Engineer. 5.6.1.2 BELL FOOTINGS Bell footings will be measured by the cubic meter, ‘computed by using the dimensions and shape specified in the contract documents or as revised in diameter by the Engineer. The bell shall consist of the volume outside the plan or authorized dimensions of the shaft, which will COMMENTARY 3556 SPECIFICATIONS extend to the bottom of the bell for the purpose of mea- surement, 56.1.3 TEST SHAFTS ‘Test shafts ofthe specified diameter will be measured from the elevation of the ground at the time drilling begins, by the meter of acceptable test shaft drilled. 56.1.4 TEST BELLS Test bells will be measured by the cubic meter com- puted by using the dimensions specified in Ar 56.1.2, “Bell Footings.” 54.1.5 EXPLORATION Exploration holes will be measured by the meter mea- sured from the bottom of shaft elevation tothe bottom of, the exploration hole, for each authorized hole drilled. 5.6.1.6 PERMANENT CASING Permanent casing will be measured by the meter for cach size of casing authorized to be used. Measurement be along the casing from top of casing or top of shaft, whichever is lower, to the bottom of the easing at ceach shaft location where permanent casing is authorized and used. 5.6.1.7 LOAD TESTS Load tests will be measured by the number of load tests performed for each designated pile load capacity. 5.6.2 Payment 56.2.1 DRILLED SHAFT Drilled shafis willbe paid for atthe contract price per meter for drilled shaft of the diameter specified. Such ‘payment shall be considered to be full compensation for all costs involved with shaft excavation, disposal of excavated material, and the furnishing and placing of concrete and reinforcing stel, including all labor, mate- rials, equipment, temporary casing, and incidentals nec- essary to complete the drilled shafts. 56.2.2 BELL FOOTINGS Bell footings constructed to the specified or autho- rized dimensions will be paid for at the contract unit price per cubic meter for bell footings. Such payment Section $—Drilled Pies and Shafts COMMENTARYAASHTO LRFD Bridge Construction Specifications ‘SPECIFICATIONS shall be full compensation for excavation and concrete beyond the diameter of the drilled shaft, including all labor, materials, equipment, and incidentals necessary to complete the bell footings. 5.62.3 TEST SHAFTS ‘Test shafts of the specified diameter will be paid for at the contract unt price per meter for test shafts, Such pay- ‘ment shall be full compensation for excavation and con- crete or backfill material, including all labor, materials, equipment, and incidentals necessary to complete the test shafts, 5.6.2.4 TEST BELLS Test bells of the diameter and shape specified or authorized and approved will be paid for at the contract unit price per cubic meter for test bells. Such payment shall be full compensation for excavation and conerete or backfill material, including all labor, materials, equip- ‘ment, and incidentals necessary to complete the test bells. 5.6.2.5 EXPLORATION HOLES Exploration holes will be paid for at the contract unit price per meter for exploration holes. Such payment shall be full compensation for drilling or coring the holes, extracting and packaging the samples or cores, and deliv- ering them to the Owner and for all other expenses nec- essary to complete the work. 5.6.2.6 PERMANENT CASING Permanent casing will be paid for at the contract unit price per meter for permanent casing. Such payment shall be full compensation for furnishing and placing the ceasing, above the costs attributable to the work paid for under associated pay items. 5.6.2.7 LOAD TESTS Load tests will be paid for at the contract unit price for each load test. Such payment shall be full compensation forall costs related to the performance of the load tests. COMMENTARY 56SECTION 6 GROUND ANCHORS61 62 63 65 66 Table of Contents SPECIFICATIONS AND COMMENTARY DESCRIPTION WORKING DRAWINGS... MATERIALS. 63.1 Prestressing Steel 632 Grout. 6.3.3. Steel Elements.. 63.4 Corrosion Protection Elements 638 Miscellaneous Elements. FABRICATION. 64.1 Bond Length and Tendon Bond Length 64.1.1 GROUT-PROTECTED GROUND ANCHOR TENDON. 64.1.2. ENCAPSULATION-PROTECTED GROUND ANCHOR TENDON 642 Unbonded Length... 643 Anchorage and Trumpet 644 Tendon Storage and Handling INSTALLATION. 65.1 Drilling.. 65.2 Tendon Insertion 653 Grouting. 65.4 Trumpet and Anchorage 65.5 Testing and Stressing 65.5.1 TESTING EQUIPMENT. 65.5.2. PERFORMANCE TEST... 6.5.5.3 PROOF TEST. 6.5.5.4 CREEP TEST 65.5.5 GROUND ANCHOR LOAD TEST ACCEPTANCE CRITERIA. 6.5.6 LOCK OFF 6-13, vn 6-14 6-15 MEASUREMENT AND PAYMEN o15 Gill‘SPECIFICATIONS COMMENTARY. SECTION 6—GROUND ANCHORS 6.1 DESCRIPTION ‘This work shall consist of designing, furnishing, installing, testing, and sessing permanent cement- grouted ground anchors in accordance with these spet cations and the contract documents. 6.2 WORKING DRAWINGS At least four weeks before work is to begin, the Con- tractor shall submit to the Engineer for review and approval complete working drawings and design calculations describing the ground anchor system or sys- tems intended for use. The submittal shall include the following: (1) A ground anchor schedule giving: + Ground anchor number, + Ground anchor design load, ‘+ Type and size of tendon, ‘+ Minimum total anchor length, ‘+ Minimum bond length, + Minimum tendon bond length, and ‘+ Minimum unbonded length. (2) A drawing of the ground anchor tendon and the cor- rosion protection system, including details for’ the following: + Spacers separating elements of tendon and their location, ‘+ Centralizers and their location, ‘+ Unbonded length corrosion protection system, + Bond length corrosion protection system, 61 C61 If there is any doubt as to the feasibility of using. ground anchors for a particular project, special test anchors should be called for in the contract documents, Production anchors are often non-redundant structural members, difficult to inspect, and located in critical sup- port areas. Assurance of success may be worth the added expense. ce 2 ‘The contract documents generally give the Contractor considerable latitude in the selection of materials and ‘method of installation that may be used; therefore, com- plete working drawings are required to control the work.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS + Anchorage and trumpet, + Anchorage corrosion protection system, + Drilled or formed hole size, + Level of cach stage of grouting, and + Any revisions to structure details necessary to accommodate the ground anchor system intended for use. (3) The grout mix design and procedures for placing the grout ‘The Engineer shall approve or reject the Contractor's ‘working drawings within four weeks of receipt of a com- plete submittal. No work on ground anchors shall begin until working drawings have been approved in writing by the Engineer. Such approval shall not relieve the Con- tractor of any responsibility under the contract docu- ‘ments for the successful completion of the work. 63 MATERIALS 63.1 Prestressing Steel Ground anchor tendons shall consist of single or mul- tiple elements of prestressing steel, anchorage devices, and, if required, couplers conforming to the requirements described in Section 10, “Prestressing.” The following materials are acceptable for use as ground anchor tendons: + AASHTO M 203M (ASTM A 416—uncoated, 7- wire strand) + ASTM A 886M (indented, 7-wire strand) + ASTM A 882M (epoxy-coated, 7-wire strand) 62 63 COMMENTARY C631 A positive Hoyer effect is present in all pretensioned bonded members. The strand is pulled to and held at a high tension while concrete is cast around it and cured. In the tensioned state, the diameter of the strand is reduced ‘compared to the diameter in an untensioned state, When the tension in the strand is transferred from the external anchors to the concrete, the stress in the strand at the end Of the concrete member goes from a high stress to zero stress. At the points of reduced stress and zero stress, the diameter of the wires increases and the wires press tightly against the surrounding concrete, creating a high friction that is an important factor in transferring the total force. This is called the Hoyer effect, identified by Jack R, Janney in “Nature of Bond in Prestressed Concrete,” Journal of American Concrete Institute, Volume 25, May 1954, ‘When a pull-out load is applied to an untensioned smooth wire strand as itis in a ground anchor, the reduc- tion in the strand diameter due to a negative Hoyer effect significantly decreases the capacity of the strand to trans- fer its tension to the concrete surrounding it.63 SPECIFICATIONS 632 Grout ‘Cement shall be Type I, I, or Il portland cement con- forming to AASHTO M 85 (ASTM C150). Cement used for grouting shall be fresh and shall not contain any lumps or other indications of hydration or “pack set Aggregate shall conform to the requirements for fine ‘aggregate described in Section 8, “Concrete Structures.” Admixtures may be used in the grout, subject to the approval of the Engineer. Expansive admixtures may only be added to the grout used for filling sealed encap- sulations, trumpets, and anchorage covers. Accelerators shall not be used. ‘Water for mixing grout shall be potable, clean, and free of injurious quantities of substances known to be harmful to portland cement or prestressing steel. 63.3 Steel Elements Bearing plates shall be fabricated from steel conform= ing to AASHTO M 270M (ASTM A 709M), Grade 250 minimum, or be a ductile iron casting conforming to ASTM A 536. ‘Trumpets used to provide a transition from the anchorage to the unbonded length corrosion protection shall be fabricated from a stel pipe or tube conforming to the requirements of ASTM A 53 for pipe or ASTM A. 500 for tubing. Minimum wall thickness shall be 5 mm. Anchorage covers used to enclose exposed anchor- ages shall be fabricated from stel, steel pipe, steel tube, ‘of ductile cast iron conforming to the requirements of AASHTO M 270M (ASTM A 709M), Grade 250 for steel, ASTM A 53 for pipe, ASTM A $00 for tubing, or ASTM A 536 for ductile cast iron, Minimum thickness shall be 3 mm. 63 Section 6—Ground Anchors COMMENTARY the adhesive bond of the indented strand decreases in the same manner as that of smooth wire strand, but the mechanical bond provided by concrete in the indenta- tions remains effective, giving the indented strand much higher capacity to transfer its tension under a pull-out loading. ‘The tension in an epoxy-coated strand is transferred to the concrete by the embedment of the grit on its surface into the concrete around it. The reduction in strand diam- eter due to the negative Hoyer effect is not large enough to have any significant effect on the strand’s capacity to transfer tension, 63.2 Although sand is not generally used in grouting small- diameter holes, it may have advantages in larger diame- ter holes. Fly ash and pozzolans are also occasionally used as filler material. Accelerators are not permitted because of concern that some may cause corrosion of the prestressing steel.AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS COMMENTARY 63 634 Corrosion Protection Elements Corrosion-inhibiting grease shall conform to the requirements of Specifications for Unbonded Single ‘Strand Tendons, Section 3.2.5, published by the Post- Tensioning Institute. ‘Sheath for the unbonded length of a tendon shall con- sist of one of the following: + Scamless polyethylene (PE) tube having a mini- ‘mum wall thickness of 1.5 mm + 0.25 mm. Poly- ethylene shall be classified by ASTM D 3350. + Scamless polypropylene tube having a minimum wall thickness of 1.5 mm + 0.25 mm, Polypropy- lene shall be classified by ASTM D 4101. + Heat-shrinkable tube consisting of a radiation cross-linked polyolefin tube internally coated with an adhesive sealant. The minimum tube wall thick: ness before shrinking shall be 0.60 mm. The mini ‘mum adhesive sealant thickness shall be 0.5 mm. *+ Corrugated polyvinyl chloride (PVC) tube having minimum wall thickness of 0.8 mm, Encapsulation for the tendon bond length shall consist of one of the following: + Corrugated high-density polyethylene (HDPE) tube having a minimum wall thickness of 0.8 mm. and conforming to AASHTO M 252 requirements. *+ Deformed steel tube or pipe having a minimum wall thickness of 0.63 mm. + Corrugated PVC tube having a minimum wall thickness of 0.8 mm, ‘+ Fusion-bonded epoxy conforming to the require- ments of AASHTO M 284M (ASTM D 3963M), except that it shall have @ film thickness of 0.38 mm, 635 Miscellaneous Elements Bondbreaker for a tendon shall consist of smooth plastic tube or pipe that is resistant to aging by ultraviolet light and that is capable of withstanding abrasion, ‘impact, and bending during handling and installation. ‘Spacers for separation of elements of a multi-clement tendon shall permit the free flow of grout. They shall be fabricated from plastic, steel, or material that is not detri- ‘mental to the prestressing steel, Wood shall not be used. 6-464 ‘SPECIFICATIONS Centralizers shall be fabricated from plastic, steel, or ‘material that is not detrimental to either the prestressing steel or any element of the tendon corrosion protection, Wood shall not be used. The centralizer shall be able to ‘maintain the position of the tendon so that a minimum of 12. mm of grout cover is obtained on the tendons or over the encapsulation, 64 FABRICATION ‘Tendons for ground anchors may be either shop- or ficld-fabricated from materials conforming to the requirements of Article 6.3, “Materials.” Tendons shall be fabricated as shown on the approved working draw- ings. The tendon shall be sized so that the maximum test load does not exceed 80 percent of the minimum guaran- teed ultimate strength of the tendon. 64.1 Bond Length and Tendon Bond Length ‘The Contractor shall determine the bond length neces- sary to satisfy the load test requirements. The minimum bond length shall be 3000 mm in rock, 4500 mm in soil, or the minimum length shown in the contract documents. ‘The minimum tendon bond length shall be 3000 mm. 6.4.1.1 GROUT-PROTECTED GROUND ANCHOR TENDON ‘Spacers shall be placed along the tendon bond length of multi-element tendons so that the prestressing steel will bond to the grout. They shall be located at 3000 mm ‘maximum centers with the upper one located a maximum of 1500 mm from the top of the tendon bond length and the lower one located a maximum of 1500 mm from the bottom of the tendon bond length. Centralizers shall be placed along the bond length. ‘They shall be located at 3000 mm maximum centers with the upper one located a maximum of 1500 mm from the top of the bond length and the lower one located 300 mm from the bottom of the bond length. Centralizers are not required on tendons installed utilizing a hollow-stem auger if itis grouted through the auger and the drill hole is maintained full of a stiff grout (225 mm slump or less) during extraction of the auger. A combination central- ier-spacer may be used. Centralizers are not required on tendons installed uti- lizing a pressure injection system in coarse-grained soils using grouting pressures greater then | MPa. 6-5 ‘Section 6—Ground Anchors COMMENTARY 6.4.1.1 Experience has shown that sufficient grout cover is ‘maintained around pressure-grouted anchors installed in coarse-grained soils without the use of centralizers.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS 64 COMMENTARY 6.4.1.2 ENCAPSULATION-PROTECTED GROUND ANCHOR TENDON ‘The tendon bond length shall be encapsulated by a grout filled corrugated plastic or deformed steel tube, oF by a fusion-bonded epoxy coating. The tendon shall be routed inside the encapsulation either prior to inserting the tendon in the dill hole or after the tendon has been placed in the drill hole. Punching holes in the encapsula- tion and allowing the grout to flow from the encapsula- tion tothe drill hole, or vice versa, shall not be permed. The tendon shall be centralized within the encapsulation and the tube sized to provide an average of 5 mm of Tout cover forthe prestessing steel. For grout-protected ground anchor tendons, spacers and centralizers shall be used to satisfy the same requirements specified in Article 6.4.1, “Grout Protected Ground Anchor Tendon.” The anchorage device of tendons protected with fusion- bonded epoxy shall be electrically isolated from the structure. 642 Unbonded Length ‘The unbonded length of the tendon shall be a mini- ‘mum of 4600 mm or as indicated in the contract docu- ments or approved working drawings. Corrosion protection shall be provided by a sheath completely filled with corrosion-inhibiting grease or ‘grout, or a heat-shrinkable tube. If grease is used to fill the sheath, provisions shall be made to prevent it from escaping at the ends. The grease shall completely coat the tendon and fill the interstices between the wires of seven-wire strands. Continuity of corrosion protection shal be provided at the transition from the bonded length tounbonéed length of the tendon. Ifthe sheath provided is not a smooth tube, then asep- arate bondbreaker must be provided to prevent the ten- ddon from bonding to the anchor grout surrounding the unbonded length. 6A3 Anchorage and Trumpet Nonrestressable anchorages may be used unless restressable anchorages are specified in the contract doc- uments Bearing plates shall be sized so that the bending stresses in the plate and average bearing stress on the concrete, if applicable, do not exceed the nominal resis- tances described in the AASHTO LRFD Bridge Design Specifications, Antcle 5.10.9:7.2. The size of bearing plates shall not be less than that shown in the contract, documents or on the approved working drawings. 6-6 6.4.1.2 Fusion-bonded epoxy encapsulations may have holi- days present in the coating. Electrical isolation of the tendon from the structure will prevent the development of a long-line galvanic corrosion cell between the struc- ‘ure and the tendon bond length portion. C643 ‘The nominal resistance of bearing plates refers to Article 5.10.9.7.2, “Bearing Resistances,” of the LRFD Bridge Design Specifications, 1994,65 SPECIFICATIONS ‘The trumpet shall be welded to the bearing plate. The trumpet shall have an inside diameter at least 6 mm areater than the diameter of the tendon at the anchorage. The trumpet shall be long enough to accommodate movements of the structure during testing and stressing. For strand tendons with encapsulation over the unbonded length, the trumpet shall be long enough to enable the tendons to make a transition from the diameter of the ten- don in the unbonded length to the diameter ofthe tendon at the anchorhead without damaging the encapsulation. ‘Trumpets filled with corrosion-inhibiting grease shall have a permanent Buna-N rubber or approved equal seal provided between the trumpet and the unbonded length corrosion protection. Trumpets filled with grout shall have a temporary seal provided between the trumpet and. the unbonded length corrosion protection. 644 Tendon Storage and Handling ‘Tendons shall be stored and handled in such a manner as to avoid damage or corrosion, Damage to tendon pre- stressing steel as a result of abrasions, cuts, nicks, welds, and weld splatter will be cause for rejection by the Engi- reer. Grounding of welding leads to the prestressing steel is not permitted. A slight rusting, provided it is not sufficient to cause pits visible to the unaided eye, shall not be cause for rejection. Prior to inserting a tendon into the drilled hole, its corrosion protection elements shall be examined for damage. Any damage found shall be repaired in a manner approved by the Engineer. Repairs to encapsulation shail be in accordance with the tendon Supplier's recommendations, 65 INSTALLATION ‘The Contractor shall select the drilling method, the routing procedure, and grouting pressure to be used for the installation of the ground anchor as necessary to sat- isfy the load test requirements, 65.1. Drilling The drilling method used may be core drilling, rotary drilling, percussion drilling, auger drilling, or driven cas- ing. The method of drilling used shall prevent loss of ground above the drilled hole that may be detrimental to the structure or existing structures. Casing for anchor holes, if used, shall be removed, unless permitted by the Engineer to be left in place. The location, inctination, and alignment of the drilled hole shall be as shown in the 67 Section 6—Ground Anchors (COMMENTARY Smooth sheathing may be repaired with ultra-high ‘molecular weight polyethylene (PE) tape, spiral wound around the tendon so as to completely seal the damaged area. The pitch of the spiral is to be such that a double thickness of tape is ensured at all points. C65.1 The longitudinal axis of the drilled hole and that of the tendon must be parallel. The tendon must not be bent to accommodate connecting the bearing plate to the structure.AASHTO LRED Bridge Construction Specifications SPECIFICATIONS contract documents. Inclination and alignment shall be within +3° of the planned angle at the bearing plate, and within $300 mm of the planned location at the ground surface (point of entry). 65.2 Tendon Insertion ‘The tendon shall be inserted into the drilled hole to the desired depth without difficulty. When the tendon cannot be completely inserted, it shall be removed and the drill hole cleaned or redrilled to permit insertion, Par- tially inserted tendons shall not be driven or forced into the hole. 653. Grouting A neat cement grout or sand-cement grout conform- ing to Article 6.3.2, "Grout,” shall be used. Admixtures, if used, shall be mixed in quantities not to exceed the ‘Manufacturer's recommendations. ‘The grouting equipment shall produce a grout free of lumps and undispersed cement. A positive-displacement grout pump shall be used. The pump shall be equipped with a pressure gauge to monitor grout pressures. The pressure gauge shall be capable of measuring pressures of atleast | MPa or twice the actual grout pressures used, whichever is greater. The grouting equipment shall be sized to enable the grout to be pumped in one continuous operation. The mixer shall be capable of continuously agitating the grout. ‘The grout shall be injected from the lowest point of the drill hole. The grout may be pumped through grout tubes, casing, hollow-stem augers, or drill rods. The _Brout may be placed before or after insertion of the ten- don. The quantity of the grout and the grout pressures shall be recorded. The grout pressures and grout takes shall be controlled to prevent excessive heave of the ‘ground or fracturing of rock formations. Except where indicated below, the grout above the top of the bond length may be placed at the same time as the bbond length grout, but it shall not be placed under pres- sure. The grout at the top of the drill hole shall stop 150 ‘mm from the back of the structure or from the bottom of the trumpet, whichever is lowest. If the ground anchor is installed in a fine-grained soil ‘using a drilled hole larger than 150 mm in diameter, then the grout above the top of the bond length shall be placed after the ground anchor has been load tested. The entire drill hole may be grouted at the same time if it can be demonstrated that the ground anchor system does not derive a significant portion of its load resistance from the soil above the bond length portion of the ground anchor. 6-8 COMMENTARY 6565 SPECIFICATIONS Pressure grouting techniques shall be utilized if grout- protected tendons are used for ground anchors in rock. Pressure grouting requires that the drill hole be sealed and that the grout be injected until a 0.35 MPa grout pressure can be maintained on the grout within the bond length for a period of five minutes. ‘Upon completion of grouting, the grout tube may remain in the drill hole provided its filled with grout. After grouting, the tendon shall not be loaded for a ‘minimum of three days. 65.4 ‘Trumpet and Anchorage ‘The corrosion protection surrounding the unbonded length of the tendon shall extend into the trumpet a mini- ‘mum of 150 mm beyond the bottom seal in the trumpet. ‘The corrosion protection surrounding the unbonded length of the tendon shall not contact the bearing plate or the anchorhead during load testing or stressing. “The bearing plate and anchoriead shall be placed per- pendicular tothe axis ofthe tendon. ‘The trumpet shall be completely filled with corrosi inhibiting grease or grout. The grease may be placed any time during construction. The grout shall be placed after the ground anchor has been load tested. The Contractor shall demonstrate that the procedures selected for place- ment of either grease or grout will produce a completely filled trumpet. ‘Anchorages not encased in concrete shall be covered with a corrosion-inhibiting grease-filled or grout-filled steel enclosure. 65S Testing and Stressing Each ground anchor shall be load tested by the Con- tractor using either the performance test or the proof test procedures specified herein. No load greater than 10 per- cent of the design load may be applied to the ground anchor prior to load testing. The test load shall be simul- taneously applied to the entire tendon. 6.5.5.1 TESTING EQUIPMENT ‘A dial gauge or vemnier scale capable of measuring displacements to 0.025 jum shall be used to measure ground anchor movement. It shall have adequate travel 0 total ground anchor movement can be measured with- cout resetting the device. A hydraulic jack and pump shall be used to apply the test load. The jack and a calibrated pressure gauge shall be used to measure the applied load. The pressure gauge shall be graduated in 0.70 MPa increments or less. When. the theoretical elastic elongation of the total anchor 69 Section 6—Ground Anchors COMMENTARY C684 ‘The most critical area to protect from corrosion is in the vicinity of the anchorage. Below the bearing plate, the corrosion protection over the unbonded length is usu- ally terminated to expose the bare tendon. Above the bearing plate, the bare tendon is gripped by either wedges, nuts, or deformations in the case of wires. Regardless of the type of tendon, the gripping mecha- nism creates stress concentrations at the connection. In addition, an aggressive corrosive environment may exist at the anchorhead since oxygen is readily available. The vulnerability of this area is demonstrated by the fact that ‘most tendon failures occur within a short distance of the anchothead. Extreme care is required in order to ensure that the prestressing stee! is well protected in this area. 6.55.1AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS 65 COMMENTARY length at the maximum test load exceeds the ram travel ofthe jack, the procedure for recycling the jack ram shall be included on the working drawings. Each increment of test load shall be applied as rapidly as possible. ‘A calibrated reference pressure gauge shall be avail able at the site. The reference gauge shall be calibrated with the test jack and pressure gauge. ‘An electrical resistance load cell and readout shall be provided when performing a creep test. ‘The stressing equipment shall be placed over the ‘ground anchor tendon in such a manner that the jack, bearing plates, load cell, and stressing anchorage are axi- ally aligned with the tendon and the tendon is centered within the equipment. 6.5.5.2 PERFORMANCE TEST Five percent of the ground anchors or a minimum of three ground anchors, whichever is greater, shall be per- formance tested in accordance with the following proce- dures. The Engineer shal select the ground anchors to be performance tested. The remaining anchors shall be tested in accordance with the proof test procedures. ‘The performance test shall be made by incrementally loading and unloading the ground anchor in accordance with the following schedule unless a different maximum test load and schedule are indicated in the contract documents: + The load shall be raised from one increment to another immediately after recording the ground anchor movement. ‘The ground anchor movement shall be measured and recorded to the nearest 0.025 jum with respect to an independent fixed reference point at the alignment load and at each increment of load, ‘The load shall be monitored with a pressure gauge. ‘The reference pressure gauge shall be placed in series with the pressure gauge during each perfor- ‘mance test. If the load determined by the reference pressure gauge and the load determined by the pressure gauge differ by ‘more than 10 percent, the jack, pressure gauge, and refer- ence pressure gauge shall be recalibrated. At load incre- ‘ments other than the maximum test load, the load shall bbe held just long enough to obtain the movement reading. Experience has shown that electrical resistance load cells frequently do not perform satisfactorily under field conditions. Hence, they are not recommended for mea- surement of load. Load cells are, however, very sensitive to small changes in load and are used to monitor changes in load during a creep test. 655.2 If a different maximum test load is to be required, a schedule similar to this one should be described in the ‘contract documents. ‘The alignment load is a small load, normally less than 10 percent of the design load, applied to the ground anchor in order to keep the testing equipment in position during testing.65 ‘SPECIFICATIONS Section 6—Ground Anchors COMMENTARY Table 65.5.2-1 Performance Test Schedule Load Load (cont'd) AL AL 0.25DL* 0.25DL, AL SDL, 0.25DL, 0.75DL, 0.S0DL* 1,00DL AL 1.20DL* 0.25DL, AL 0.S0DL, 0.25DL, 0.75DL* 0.50DL, AL 0.75DL 0.25DL 1.00DL 0.S0DL, 1.2001. 0.751. 1.33DL* (Max. test load) 1.00DL* Reduce to lock-off load Article 6.5.5.6) where: AL = Alignment Load DL = Design Load for ground anchor * = Graph required. (See last paragraph inthis Article.) ‘The maximum test load in a performance test shall be held for 10 minutes. The jack shall be repumped as nec essary in order to maintain a constant load. The load- hold period shall start as soon as the maximum test load is applied, and the ground anchor movement shall be measured and recorded at I minute, 2, 3, 4, 5, 6, and 10 ‘minutes. If the ground anchor movement between 1 ‘minute and 10 minutes exceeds 1.0 mm, the maximum test load shall be held for an additional 50 minutes. If the load-hold is extended, the ground anchor movement shall be recorded at 15 minutes, 20, 25, 30, 45, and 60 ‘minutes. ‘A graph shall be constructed showing a plot of ground anchor movement versus load for each load increment ‘marked with an asterisk (*) in Table 6.5.5.2-I and a plotAASHTO LRFD Bridge Construction Specifications SPECIFICATIONS of the residual ground anchor movement of the tendon at each alignment load versus the highest previously applied load. Graph format shall be approved by the Engineer prior to use. 65.53 PROOF TEST ‘Those anchors not subjected to a performance test shall be tested as specified herein. ‘The proof test shall be performed by incrementally loading the ground anchor in accordance with the follow- ing schedule unless a different maximum test load and schedule are indicated in the contract documents. The load shall be raised from one increment to another imme- diately after recording the ground anchor movement. The ground anchor movement shall be measured and recorded to the nearest 0,025 jum with respect to an inde- pendent fixed reference point at the alignment load and at each increment of load. The load shall be monitored with a pressure gauge. At load increments other than the ‘maximum test load, the load shall be held just long enough to obtain the movement reading. Table 65.5.3-1 Proof Test Schedule Load Load AL 1,00DL. 0.25DL_ 1.20DL 0.50DL, 1.33DL (Max. test load) 0.75DL, Reduce to lock-off load where: AL = Alignment Load DL = Design Load for ground anchor ‘The maximum test load in a proof iest shall be held for 10 minutes. The jack shall be repumped as necessary in order to maintain a constant load. The load-hold period shall start as soon as the maximum test load is applied, and the ground anchor movement shall be mea- sured and recorded at | minute, 2,3, 4, 5, 6, and 10 min- tutes. If the ground anchor movement between 1 minute and 10 minutes exceeds 1.0 mm, the maximum test load shall be held for an additional 50 minutes. If the load- hold is extended, the ground anchor movement shall be recorded at 15 minutes, 20, 30, 45, and 60 minutes. A. graph shall be constructed showing a plot of ground 65 COMMENTARY. 6.5.5.3, If a different maximum test load is to be required, a schedule similar to the one given in this article should be described in the contract documents.65 ‘SPECIFICATIONS Section 6—Ground Anchors COMMENTARY anchor movement versus load for each load increment in the proof test. Graph format shall be approved by the Engineer prior to use. Creep tests shall be performed if specified in the con- tract documents. The Engineer shall select the ground anchors to be creep tested. ‘The creep test shall be made by incrementally loading, and unloading the ground anchor in accordance with the performance test schedule used. At the end of each load- ing cycle, the load shall be held constant for the observa- tion period indicated in the creep test schedule below unless a different maximum test load is indicated in the contract documents. The times for reading and recording the ground anchor movement during each observation period shall be 1 minute, 2, 3, 4, 5, 6, 10, 15, 20, 25, 30, 45, 60, 75, 90, 100, 120, 150, 180, 210, 240, 270, and 300 minutes as appropriate. Each load-hold period shall Start as soon as the test load is applied. In a creep test, the pressure gauge and reference pressure gauge shall be used to measure the applied load, and the load cell shall bee used to monitor small changes of load during a con- stant load-hold period. The jack shall be repumped as necessary in order to maintain a constant load. Table 655.1 Creep Test Schedule aL 025 10 0.500 30 0.750 30 1.000 45 1200 6 133DL 300 A graph shall be constructed showing a plot of the ground anchor movement and the residual movement ‘measured in a creep test as described for the performance test. Also, a graph shall be constructed showing a plot of the ground anchor creep movement for each load-hold as, 4 function of the logarithm of time, Graph formats shall bbe approved by the Engineer prior to use. 65.5.4 If creep tests are required, at least two ground anchors should be creep-tested. If a different maximum test load is to be required, a schedule similar to this one should be described in the contract documents,AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS 6.5.5.5 GROUND ANCHOR LOAD TEST ACCEPTANCE CRITERIA A performance-tested or proof-tested ground anchor with a 10-minute load-hold shall be deemed to be accept- able ifthe: + Ground anchor resists the maximum test load with less than 1.0 mm of movement between | minute and 10 minutes; and + Total movement at the maximum test load exceeds 80 percent of the theoretical elastic elongation of the unbonded length, For a performance-tested ground anchor in competent rock, the total movement at the maximum test load may not exceed the theoretical clastic elongation of the unbonded length plus 50 percent of the theoretical elastic elongation of the bonded length. ‘A performance-tested or proof-tested ground anchor with a 60-minute load-hold shall be deemed to be accept- able ifthe: + Ground anchor resists the maximum test load with creep rate that does not exceed 2.0 mm in the last log cycle of time; and + Total movement atthe maximum test load exceeds 80 percent of the theoretical elastic elongation of the unbonded length. For a performance-tested ground anchor in competent rock, the total movement at the maximum test load may not exceed the theoretical elastic elongation of the ‘unbonded length plus 50 percent of the theoretical elastic elongation of the bonded length. A creep-tested ground anchor shall be deemed to be acceptable if the: + Ground anchor carries the maximum test load with creep rate that does not exceed 2.0 mm in the last log cycle of time; and + Total movement at the maximum test load exceeds 80 percent of the theoretical elastic elongation of the unbonded length. For a performance-tested ground anchor in competent rock, the total movement at the maximum test load may not exceed the theoretical elastic elongation of the ‘unbonded length plus 50 percent of the theoretical elastic clongation of the bonded length. 6-14 COMMENTARY 6566 SPECIFICATIONS Section 6—Ground Anchors COMMENTARY If the total movement of the ground anchor at the ‘maximum test load does not exceed 80 percent of the theoretical elastic elongation of the unbonded length, the ground anchor shall be replaced at the Contractor's expense. ‘A ground anchor that has a creep rate greater than 2.0 ‘mm per log cycle of time can be incorporated into the structure, but its design nominal resistance shall be equal to one-half of its failure load. The failure load is the load resisted by the ground anchor after the load has been allowed to stabilize for 10 minutes. ‘When a ground anchor fails, the Contractor shall ‘modify the design and/or the installation procedures, ‘These modifications may include, but are not limited to, installing a replacement ground anchor, reducing the design load by increasing the number of ground anchors, ‘modifying the installation methods, increasing the bond length, or changing the ground anchor type. Any modi cation that requires changes to the structure shall be approved by the Engineer. Any modifications of design ‘or construction procedures shall be without additional ccost to the Owner and without extension of the contract, documents time. Retesting of a ground anchor will not be permitted, except that regrouted ground anchors may be retested. 65.56 LOCK OFF Upon successful completion of the load testing, the ‘ground anchor load shall be reduced to the lock-off load indicated in the contract documents and transferred to the anchorage device. The ground anchor may be completely unloaded prior to lock-off. After transferring the load and prior to removing the jack, a lift-off load reading shall be made. The lift-off load shall be within 10 percent of the specified lock-off load. Ifthe load is not within 10 percent of the specified lock-off load, the anchorage shall be reset and another lift-off load reading shall be made, This process shall be repeated until the desired lock-off load is obtained. 6.6 MEASUREMENT AND PAYMENT Ground anchors will be measured and paid for by the ‘umber of units installed and accepted as shown in the contract documents or ordered by the Engineer. No change in the number of ground anchors to be paid for will be made because of the use by the Contractor of an alternative number of ground anchors. 6-15 6.6 Some agencies prefer to pay for performance tests and creep tests separately to avoid the uncertainty of testing costs. Local experience will determine the desirability of such separate pay clauses.AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS The contract unit price paid for ground anchors shall include full compensation for furnishing all labor, mate- rials, tools, equipment, and incidentals, and for doing all the work involved in installing the ground anchors (including testing), complete in place, as specified in these specifications, the contract documents, and as directed by the Engineer. COMMENTARY 66SECTION 7 EARTH RETAINING SYSTEMSTable of Contents SPECIFICATIONS AND COMMENTARY 7.1 DESCRIPTION ..... 7.2 WORKING DRAWINGS. 73 MATERIALS .. 73. Concrete... 73.L1 CASTIN-PLACE.. 73.12 PNEUMATICALLY APPLIED MORTAR .. 73.13. PRECAST ELEMENTS... | 73.14 SEGMENTAL CONCRETE FACING BLOCKS 73.2 Reinforcing Steel. 733 Structural Sted.. 734 Timber... 735. Drainage Elements 73.5.1 PIPE AND PERFO! 7352. FILTER FABRIC. 7353 PERMEABLE MATERIAL 7334 GEOCOMPOSITE DRAINAGE SYSTEMS. 7346 Structure Backfill Material.. 736.1 GENERAL. 7362 CRIB AND CELLULAR WALLS.. 7363 MECHANICALLY STABILIZED EARTH WALLS.. 74 EARTHWORK... 741 Structure Excavation. 7.4.2 Foundation Treatment 743° Structure Backfill 18 DRAINAGE. 7.51 Concrete Gutters 152 153 7.54 Geocomposite Drainage Systems ... 7.6 CONSTRUCTION. 7.61 Concrete and Masonry Gravity Walls, Reinforeed Concrete Retaining Walls. : 7.6.2. Sheet Pile and Soldier Pile Walls. 762.1 SHEET PILE WALLS... 7.62.2. SOLDIER PILE WALLS 71623 ANCHORED SHEET PILE AND SOLDIER PILE WALLS... 7-10 1 : W Tali Pon) 076.2.3.3 Conerete Anchor System T6234 Tie-t0d8 seer 7.6.2.3. Ground Anchors. 76.2.3.6. BatthWOrk rn 7.6.3_ Crib Walls and Cellular Walls. 7.63.1 FOUNDATION. 7.6.3.2 CRIB MEMBERS nen — 7.6.3.3 CONCRETE MONOLITHIC CELL MEMBERS 7.6.3.4 MEMBER PLACEMENT. 7.635 BACKFILLING.. : 7.6.4 Mechanically Stabilized Earth Walls, 7.64.1 FACING rie 7.6.4.2 SOIL REINFORCEMENT. 764.3 CONSTRUCTION... 7.7, MEASUREMENT AND PAYMENT... tivSPECIFICATIONS COMMENTARY SECTION 7—EARTH RETAINING SYSTEMS 7.1 DESCRIPTION cra ‘This work shall consist of furnishing and installing Barth-retaining systems include concrete and masonry cearth-retaining systems in accordance with the contract gravity walls, reinforced concrete retaining walls, sheet documents and these specifications. pile and soldier pile walls (with and without ground ‘anchors or other anchorage systems), crib and cellular walls, and mechanically stabilized earth walls. 7.2 WORKING DRAWINGS Working drawings and design calculations shall be submitted to the Engineer for review and approval at least 4 weeks before work is to begin. Such submittals shall be required: + for each alternative proprietary or nonproprietary earth-retaining system proposed, as permitted or specified in the contract documents, + complete details for the system to be constructed are not included in the contract documents, and + when otherwise required by the contract docu- ments or these specifications. Working drawings and design calculations shall include the following: = Existing ground elevations that have been veri- fied by the Contractor for each location involv- ‘ng construction wholly or partially in original ‘ground. = Layout of wall that will effectively retain the earth, but not less in height or length than that shown for the wall system in the contract docu- ments, = Complete design calculations substantiating that the proposed design satisfies the design ‘parameters in the contract documents, Complete details of all elements required for the proper construction of the system, including complete material specifications. Earthwork requirements including specifica- tions for material and compaction of backfill. 7AASHTO LREFD Bridge Construction Specifications ‘SPECIFICATIONS ~ Details of revisions or additions to drainage sys- ‘tems or other facilities required to accommo- date the system, ~ Other information required in the contract docu- ments or requested by the Engineer. ‘The Contractor shall not start work on any earth- retaining system for which working drawings are required until such drawings have been approved by the Engineer. Approval of the Contractor's working draw- {ngs shall not relieve the Contractor of any responsibility under the contract documents for the successful comple- tion of the work. 7.3 MATERIALS 734 Conerete 73.11 CAST-IN-PLACE Cast-in-place conerete shall conform to the require- ‘ments of Section 8, “Concrete Structures.” The concrete shall be Class A unless otherwise indicated in the con- tract documents 7.3.1.2 PNEUMATICALLY APPLIED MORTAR Pneumatically applied mortar shall conform to the requirements of Section 24, “Pneumatically Applied Mortar.” 73.13 PRECAST ELEMENTS ‘The materials, manufacturing, storage, handling, and erection of precast concrete elements shall conform to the ‘requirements in Article 8.13, “Precast Concrete “Members.” Unless otherwise shown in the contract docu- ‘ments or on the approved working drawings, portland cement concrete used in precast elements shall conform to Class A (AB) with a minimum compressive strength at 28 days of 28 MPa. Nang eT 1-2 COMMENTARY 1313 Section 7—Earth Retaining Systems ‘SPECIFICATIONS COMMENTARY 7.3.14 SEGMENTAL CONCRETE FACING BLOCKS. Masonry concrete blocks used as wall facing elements shall have a minimum compressive strength of 28 MPa ‘and water absorption limit of 5 percent. In areas of repeated freeze-thaw cycles, the facing blocks shall be tested in accordance with ASTM C 1262 to demonstrate durability. The facing blocks shall meet the requirements of ASTM C 1372, except that acceptance regarding dura~ bility under this testing method shall be achieved if the weight loss of each of four of the five specimens at the conclusion of 150 cycles does not exceed 1 percent of its initial weight. Blocks shall also meet the additional requirements of ASTM C 140. Facing blocks directly exposed to spray from deiced pavements shall be sealed after erection with a water resistant coating or be manu factured with a coating or additive to increase freeze- thaw resistance. 73.2. Reinforcing Steel Reinforcing steel shall conform to the requirements of Section 9, “Reinforcing Steel.” 7.3.3. Structural Steel Structural steel shall conform to AASHTO M 270M (ASTM A 709M), Grade 250, unless otherwise specified in the contract documents. 7-21AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS ‘This page intentionally left blank. m mr COMMENTARY 1373 SPECIFICATIONS 734 Timber jmber shall conform to the requirements of Section 16, “Timber Structures,” and Article 4.2.2, “Timber Piles.” 7.35 Drainage Elements 73.1 PIPE AND PERFORATED PIPE Pipe and perforated pipe shall conform to the AASHTO Guide Specifications for Highway Construc- tion, GSH.-7, 1993, Subsections 708 and 709, 7352 FILTER FABRIC Fitter fabric shall conform to the AASHTO Guide Specifications for Highway Construction, GSH-1, 1993, Subsection 620. 73.53 PERMEABLE MATERIAL Permeable material shall conform to the AASHTO Guide Specifications for Highway Construction, GSH~7, 1993, Subsection 704, unless otherwise specified in the contract documents or on the approved working. drawings, 735.4 GEOCOMPOSITE DRAINAGE SYSTEMS: Geocomposite drainage systems shall conform to the requirements specified in the contract documents or the approved working drawings. 736 Structure Backfill Material 736.1 GENERAL Al structure backfill material shall consist of material free from organic material or other unsuitable material as determined by the Engineer. Gradation will be deter- mined by AASHTO T 27 (ASTM C 136). Grading shall be as follows, unless otherwise specified: Sieve Size Percent Passing 75 mm 100 475 mm 35-100 600 um 20-100 75 um ous 13 ‘Section 7—Earth Retaining Systems COMMENTARYAASHTO LRFD Bridge Construction Specifications SPECIFICATIONS 7.3.62 CRIB AND CELLULAR WALLS Structure backfill material for crib and cellular walls shall be of such character that it will not sift or flow through openings in the wall. For wall heights over 6000 mm, the following grading shall be required: Sieve Size Percent Passing 75mm 100 4.75 mm 25-100 300 um 5-20) 75 um os 73.63 MECHANICALLY STABILIZED EARTH WALLS ‘Structure backfill material for mechanically stabilized ‘earth walls shall conform to the following grading, inter- nal friction angle, and soundness requirements: Sieve Size Percent Passing 100 mm 100 425 um 0-60 75 um ous *Plasticity Index (PI), as determined by AASHTO T 90, shall not exceed 6. ‘The material shall exhibit an angle of internal friction of not less than 34°, as determined by the standard Direct Shear Test, AASHTO T 236 (ASTM D 3080), on the portion finer than the 2-mm sieve, utilizing a sample of the material compacted to 95 percent of AASHTO T 99, Method C or D (with oversized correction as outlined in Note 7) at optimum moisture content. No testing is required for backfills where 80 percent of sizes are greater than 20 mm, ‘The materials shall be substantially free of shale or ‘other soft, poor-durability particles. The material shall hhave a magnesium sulfate soundness loss of less than 30 percent after four cycles. Additionally, the backfill material shall meet the fol- lowing electrochemical requirements when steel soil reinforcement is to be used: pH of 5 to 10 Resistivity not less than 30 ohm meters Chlorides not greater than 100 parts per million ‘Sulfates not greater than 200 parts per million COMMENTARY 73 /1a ‘SPECIFICATIONS Section 7—Karth Retaining Systems COMMENTARY 74 EARTHWORK TAA Structure Excavation ‘Structure excavation for earth-retaining systems shall conform to the requirements of Section 1, “Structure Excavation and Backfill,” and as provided below. 7.4.2 Foundation Treatment Foundation treatment shall conform to the require- ments of Article 1.42, “Foundation Preparation and Control of Water,” unless otherwise specified in the con- tract documents or included in the approved working drawings. If subexcavation of foundation material is indicated, the Contractor shall perform the excavation to the limits shown. Material excavated shall be replaced with structure backfill material meeting the requirements for the particular earth-retaining system to be constructed unless a different material is specified in the contract documents. The material shall be compacted to a density not less than 95 percent of the maximum density as determined by AASHTO T 99, Method C or D (with oversize correction as outlined in Note 7). 7A3 Structure Backfill Placement of structure backfill material shall conform to the requirements of Articles 1.43, “Backfill,” and 7.6,Construction.” Material used shall conform to the requirements of Article 7.3.6, “Structure Backfill Material.” 7.8 DRAINAGE Drainage facilities shall be constructed in accordance with the details shown on the approved working drawings or in the contract documents and. these specifications. 751 Concrete Gutters Concrete gutters shall be constructed to the profile indicated in the contract documents or on the approved working drawings. Pneumatically applied mortar shall conform to the requirements of Section 24, “Pneumati- cally Applied Mortar.” Outlet works shall be provided at sags in the profile, at the low ends of the gutter, and at other indicated locations. 1SAASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS 75.2 Weep Holes Weep holes shall be constructed at the locations shown in the contract documents or on the approved working drawings. A minimum of 0.06 m? of permeable ‘material encapsulated with filter fabric shall be placed at each weep hole. Joints between precast concrete retaining wall face panels that function as weep holes shall be covered with filter fabric. The filter fabric shall be bonded to the face panels with adhesive conforming to Federal Specifica- tion MMM-A--121. The face panels that are to receive the filter fabric shall be dry and thoroughly cleaned of dust and loose materials. 753° Drainage Blankets Drainage blankets consisting of permeable material encapsulated in filter fabric, collector pipes, outlet pipes, and cleanout pipes shall be constructed as specified in the contract documents or on the approved working drawings. ‘The subgrade to receive the filter fabric shall conform to the compaction and elevation tolerance specified and shall be free of loose or extraneous material and sharp objects that may damage the filter fabric during installa- tion. The fabric shal be stretched, aligned, and placed in a wrinkle-tree manner. Adjacent borders of the fabric shall be overlapped from 300 mm to 450 mm. Should the fabric be damaged, the tom or punctured section shall be repaired by placing apiece of fabric that is large enough to cover the damaged area and to meet the overlap requirement. The permeable material shall be placed in horizontal layers and thoroughly consolidated along with and by the same methods specified for structure backfill. Ponding and jetting of permeable material or structure backfill ‘material adjacent to permeable material shall not be per- mitted. During spreading and compaction of the perme able material and structure backfill or embankment material, a minimum of 150 mm of such material shall be ‘maintained between the fabric and the Contractor's equipment. ‘The perforated collector pipe shall be placed within the permeable material to the flow line elevations shown. Outlet pipes shall be placed at sags in the flow line, at the low end ofthe collector pipe, and at other locations shown or specified in the contract documents. Rock slope protection, when required atthe end of outlet pipes, shall conform tothe details in the contract documents of approved working drawings and the requirements in Sec- tion 22, “Slope Protection.’ 1-6 COMMENTARY 1516 SPECIFICATIONS Cleanout pipes shall be placed at the high ends of col- lector pipes and at other locations as specified in the con- tract documents. 7.54 Geocomposite Drainage Systems Geocomposite drainage systems shall be installed at the locations shown in the contract documents or on the approved working drawings. The geocomposite drainage ‘material shall be placed and secured tightly against the excavated face, lagging, or back of wall as specified in the contract documents. When concrete is to be placed against geocomposite drainage material, the drainage ‘material shall be protected against physical damage and ‘grout leakage. 7.6 CONSTRUCTION ‘The construction of earth-retaining systems shall con- form to the lines and grades indicated in the contract doc ‘uments, on the working drawings, or as directed by the Engineer. 7.6.1 Concrete and Masonry Gravity Walls, Reinforced Concrete Retaining Walls ‘Stone masonry construction shall conform to the requirements of Section 14, “Stone Masonry.” Concrete construction shall conform to the requirements of Sec- tion 8, “Conerete Structures.” Reinforced concrete block masonry shall conform to the requirements of Section 15, “Concrete Block and Brick Masonry.” ‘Vertical precast concrete wall elements with east-in- place concrete footing support shall be adequately sup- ported and braced to prevent settlement or lateral dis- placement until the footing conerete has been placed and. has achieved sufficient strength to support the wall elements. The exposed face of concrete walls shall receive a Class 1 finish as specified in Section 8, “Concrete Struc- tures,” unless a special architectural treatment is speci- fied in the contract documents or on the approved working drawings. 7.6.2 Sheet Pile and Soldier Pile Walls This work shall consist of constructing continuous walls of timber, steel, or concrete sheet piles, and con- structing soldier pile walls with horizontal facing ele- ‘ments of timber, steel, or concrete. 77 Section 7—Earth Retaining Systems COMMENTARYAASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS 7.62.1 SHEET PILE WALLS Steel sheet piles shall be ofthe type and mass speci- fied in the contract documents. Steel sheet piles shall conform to the requirements of AASHTO M 202M (ASTM A 328M), AASHTO M 270M (ASTM A 709M) Grade 345, orto the specifications for “Piling for use in Marine Environments” in ASTM A 690M. Painting of steel sheet piles, when required, shall conform to Article 13.2, “Painting Metal Structures.” Timber sheet piles, unless otherwise specified or per- mitted in the contract documents, shall be treated in accordance with Section 17, “Preservative Treatment of Wood.” The piles shall be of the dimensions, species, and grade of timber specified in the contract documents, The piles may be either cut from solid material or made by building up with three planks securely fastened together. The piles shall be drift sharpened at their lower ‘ends s0 as to wedge adjacent pile tightly together during driving. Concrete sheet piles shall conform to the details spec- ified in the contract documents oF the approved working drawings. The manufacture and installation shall con- form, in general, to the requirements for precast concrete bearing piles in Section 4, “Driven Foundation Piles.” Concrete sheet piles detailed to have a tongue-and- _groove joint on the portion below ground and a double grooved joint on the exposed portion shall, after installa- tion, have the upper grooves cleaned of all sand, mud, oF debris, and grouted full. Unless otherwise provided in the contract documents or approved in writing by the Engi- neer, grout shall be composed of one part cement and two parts sand, The grout shall be deposited through a ‘grout pipe placed within a watertight plastic. sheath extending the full depth of the grout slot formed by the grooves in two adjacent pilings and that, when filled, completely fills the slot. Sheet ples shal be driven tothe specified penetration ‘or bearing capacity in accordance with the requirements of Section 4, “Driven Foundation Piles.” After driving, the tops of sheet piles shall be neatly cutoff toa straight line at the elevation specified in the contract documents or as directed by the Engineer, Sheet pile walls shall be braced by wales or other bracing system as shown in the contract documents ot directed by the Engineer. ‘Timber waling strips shall be properly lapped and joined at all splices and corners. The wales shall prefera- bly be in one length between comers and shall be bolted near the tops of the piles, ‘When specified in the contract documents or on the approved working drawings, reinforced concrete caps 18 COMMENTARY 1616 SPECIFICATIONS shall be constructed in accordance with Section 8, “Con- crete Structures.” 7.6.2.2 SOLDIER PILE WALLS Soldier piles shall be either driven piles or piles con- structed in a drilled shaft excavation to the specified pen- ‘tration or bearing capacity indicated in the contract documents. en piles shall be furnished and installed in accor- dance with the requirements of Section 4, “Driven Foun- dation Piles.” The piles shall be of the type indicated in the contract documents. Piles constructed in a drilled shaft excavation shall conform to the details shown in the contract documents. Construction of the shaft excavation and placement of cconerete of lean concrete backfill shall be in accordance ‘with Section 5, “Drilled Piles and Shafts.” The structural ‘component of the soldier pile placed in the shaft excavs tion shall be as specified in the contract documents. Reinforced concrete, either cast-in-place or precast, shall conform to the requirements of Section 8, “Concrete Structures.” Timber members shall conform to the requirements of Section 16, “Timber Structures,” and Section 17, “Preservative Treatment of Wood.” Steel members shall conform to the requirements of Section Il, “Steel Structures.” Painting of steel members, if required, shall conform to Section 13, “Painting.” ‘Concrete backfill placed around precast concrete, tim ber, or steel pile members in the drilled shaft excavation shall be commercially available portland cement con- crete with a cement content not less than 280 kg/m?. Lean concrete backfill shall consist of commercial quality concrete sand, water, and not greater than ‘56 kg/m? of portland cement. The limits for placement of concrete and lean concrete shall be specified in the con- tract documents, ‘The facing spanning horizontally between soldier piles shall conform to the materials and details in the contract documents or on the approved working draw- ings. Timber lagging shall conform to the requirements in Section 16, “Timber Structures,” and Section 17, “Pre- servative Treatment of Wood.” Precast concrete lagging fo facing panels and cast-in-place concrete facing shall ‘conform to the requirements in Section 8, “Concrete Structures.” Concrete anchors, welded connections, and bolted connections for securing facing elements to the soldier piles shall conform to the details in the contract documents. ‘The exposed surface of concrete wall facing shall receive a Class | finish as specified in Section 8, “Con- crete Structures,” unless a special architectural treatment 19 Section 7—Earth Retaining Systems COMMENTARYAASHTO LRFD Bridge Construction Specifications SPECIFICATIONS is specified in the contract documents or on the approved working drawings. 7.62.3 ANCHORED SHEET PILE AND SOLDIER PILE WALLS. 76.23.1 General ‘The construction of anchored walls shall consist of constructing sheet pile and soldier pile walls anchored with a tie-rod and concrete anchor system or with ground anchors. Sheet pile and soldier pile wall construction shall con- form to the requirements of Articles 7.6.2.1, “Sheet Pile Walls,” and 7.6.2.2, “Soldier Pile Walls,” respectively. 76.2.3.2 Wales ‘Wales consisting of either timber, steel, or concrete shall conform to the details in the contract documents or fon the approved working drawings. The alignment of wales shall be such that tie-rods or ground anchors can be installed without bending. Timber wales shall con- form to the requirements of Section 16, “Timber Struc- tures,” and Section 17, “Preservative Treatments of Wood.” Stee! wales shall conform to the requirements of Section 11, “Steel Structures.” Concrete wales shall conform to the requirements of Section 8, “Concrete Structures.” 7.6.2.3.3 Concrete Anchor System Conerete anchor systems, consisting of either drilled shafts or reinforced concrete shapes placed within the limits of soil or rock excavation, with or without pile support, shall conform to the details in the contract docu- ‘ments or on the approved working drawings, Battered anchor piles shall be driven to the proper bat- ter shown. The tension anchor piles shall be furnished with adequate means of anchorage to the concrete anchor block. Drilled shaft concrete anchors shall conform to the details in the contract documents or on the approved working drawings, and be constructed in conformance with Section 5, “Drilled Piles and Shafts.’ 1623.4 Tie-rods Tie-rods shall be round steel bars conforming to AASHTO M 270M (ASTM A 709M), Grade 250, unless otherwise specified in the contract documents, Corrosion protection shall be provided as specified in the contract 7-10 COMMENTARY 16 VY16 SPECIFICATIONS Section 7—Earth Retaining Systems COMMENTARY documents. Care shall be taken in the handling and back- filling operations to prevent damage to the corrosion pro- tection or bending ofthe tie-rod itself. ‘The connection of the tie-rods to the soldier piles, wales, wall face, and concrete anchors shall conform to the details specified in the contract documents, 7.6.2.3.5 Ground Anchors Ground anchors shall be constructed in conformance with the requirements of Section 6, “Ground Anchors.” The connection of ground anchors to soldier piles, wales, or wall face shall conform to the details in the ccontract documents or on the approved working draw- ings. 7.6:2.3.6 Earthwork Earthwork shall conform to the requirements in Arti- cle 7.4, “Earthwork.” Unless otherwise specified in the contract documents, excavation in front of the wall shall not proceed more than 900 mm below a level of tie-rods or ground anchors until such tie-rods and anchors or ground anchors are complete and accepted by the Engineer. Placement of lagging shall closely follow excavation in front ofthe wall such that loss of ground is minimized. 7.63 Crib Walls and Cellular Walls ‘This work shall consist of constructing timber, con- crete, or steel crib walls and concrete monolithic cell walls complete with backfill material within the cells formed by the members. 7.63.1 FOUNDATION In addition to the requirements of Article 7.4.2, “Foundation Treatment,” the foundation or bed course ‘material shall be finished to exact grade and cross slope so that the vertical or battered face alignment will be achieved. When required, timber mud sills, concrete leveling pads, or concrete footings shall conform to the details specified in the contract documents. Timber mud sills shall be firmly and evenly bedded in the foundation material. Concrete for leveling pads or footings shall be placed against the sides of excavation in the foundation material.AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS 7.63.2 CRIB MEMBERS Unless otherwise specified in the contract documents, timber header and stretcher members shall conform to the requirements of Section 16, “Timber Structures,” and. shall be the same as for caps, posts, and sills. Preserva: tive treatment shall conform to the requirements of Sec- tion 17, “Preservative Treatment of Wood.” The size of the members shall be as shown in the contract documents. Concrete header and stretcher members shall conform to the requirements of Section 8, “Concrete Structures,” for precast concrete members. The dimensions of the members and minimum concrete strength shall be as specified in the contract documents or on the approved working drawings. Steel crib members consisting of base plates, col- uumns, stretchers, and spacers shall be fabricated from sheet steel conforming to AASHTO M 218, Thickness of ‘members shall be as specified. Crib members shall be so fabricated that members of the same nominal size and thickness shall be fully interchangeable. No drilling, punching, or drifting to correct defects in manufacture shall be permitted. Any members having holes improp- erly punched shall be replaced. Bolts, nuts, and miscella- neous hardware shall be galvanized in accordance with AASHTO M 232 (ASTM A 153). 7.633 CONCRETE MONOLITHIC CELL MEMBERS, Concrete monolithic cell members consisting of four- sided cells of uniform height and various depths shall be cast in conformance with the requirements set forth for precast members in Section 8, “Concrete Structure ‘The minimum concrete compressive strength shall be 28 MPa. The exposed cell face shall have a Class 1 finish; faces not exposed to view shall have a uniform surface finish free of open pockets of aggregate or surface distor- tions in excess of 6 mm. The protruding keys and recesses for keys on the tops and bottoms of the side walls of the cells shall be accurately located. 7.6.3.4 MEMBER PLACEMENT ‘Timber and concrete crib members shall be placed in successive tiers at spacings conforming to the specified details for the particular height of wall being constructed. Drift bolts at the intersection of timber header and stretcher members shall be accurately installed so that ‘minimum edge distances are maintained. At the intersec- tion of concrete header and stretcher members, asphalt COMMENTARY 1616 SPECIFICATIONS felt shims or other approved material shall be used to obtain uniform bearing between the members. Steel column sections, stetchers, and spacers shall conform to the proper length and mass as specified, ‘These members shall be accurately aligned to permit completing the bolted connections without distorting the ‘members. Bolts atthe connections shall be torqued to not Tess than 34 000 N-mm. Concrete monolithic cell members of the proper sizes shall be successively stacked in conformance with the layout specified in the contract documents or on the approved working drawings. Care shall be exercised in placing the members to prevent damage to the protruding, keys. Damaged or ill-fitting keys shall be repaired using. ‘a method approved by the Engineer. 7.63.5 BACKFILLING ‘The cells formed by the wall members shall be back- filled with structure backfill material conforming to the requirements in Article 7.3.6, “Structure Backfill Mate- rial.” Backfilling shall progress simultancously with the erection of the members forming the cells. Backfill mate- rial shall be so placed and compacted as to not disturb or damage the members. Placement of backfill shall be in uniform layers not exceeding 300 mm in thickness unless otherwise proposed by the Contractor and approved by the Engineer. Compaction shall be to a density of atleast 95 percent of the maximum density as determined by AASHTO T 99, Method C. Backfilling behind the wall to the limits of excavation shall conform to the same requirements unless otherwise indicated or approved. 7.6.4 Mechanically Stabilized Earth Walls ‘The construction of mechanically stabilized earth walls shall consist of constructing a facing system to which steel or polymeric soil reinforcement is connected and placing structure backfill material surrounding the soil reinforcement. 7.6.4.1 FACING Facing consisting of either precast concrete panels, ccast-in-place concrete, or welded wire fabric shall con- form to the details and materials specified in the contract documents or on the approved working drawings. Precast concrete panels shall be cast in conformance with the requirements set forth for precast members in Section 8, “Concrete Structures.” The concrete compres- sive strength shall be that specified in the concrete docu- ‘ments or 28 MPa, whichever is greater. The exposed face shall have a Class | finish or the architectural treatment Section 7—Earth Retaining Systems COMMENTARYAASHTO LRFD Bridge Construction Specifications SPECIFICATIONS specified in the contract documents or on the approved working drawings. The face not exposed to view shall have a uniform surface finish free of open pockets of aggregate or surface distortions in excess of 6 mm, Soil reinforcement connection hardware shall be accurately located and secured during concrete placement and shall not contact the panel reinforcing steel. Joint filler, bear- ing pads, and joint cover material shall be as specified in the contract documents. Cast-in-place concrete facing shall be constructed in conformance with the requirements in Section 8, “Con- crete Structures.” Soil reinforcement extending beyond the temporary facing shall be embedded in the facing Concrete a depth equal to the minimum dimensions spec- ified in the contract documents or on the approved work- ing drawings. Welded wire facing, either temporary or permanent, shall be formed by @ 90° bend ofthe horizontal soil forcement, The vertical portion ofthe soil reinforcement forming the face shall be connected to the succeeding upper level of soil reinforcement. A separate backing ‘mat and hardware cloth shall be placed immediately behind the vertical portion of soil reinforcement. Its wire size and spacing shall be as specified in the contract documents. 7.6.4.2 SOIL REINFORCEMENT Al steel soil reinforcement and any steel connection hhardware shall be galvanized in accordance with AASHTO M 111 (ASTM A 123), Steel strip reinforcement shall be hot rolled to the required shape and dimensions. The stcel shall conform to AASHTO M 223M (ASTM A 572M), Grade 450, unless otherwise specified in the contract documents. Welded wire fabric reinforcement shall be shop fabri- cated from cold-drawn wire of the sizes and spacings specified in the contract documents or on the approved working drawings. ‘The wire shall conform to the requirements of AASHTO M 32M (ASTM A 82). Fabri cated fabric shall conform to the requirements of ‘AASHTO M 55M (ASTM A 185). Polymeric reinforcement shall be of the type and size specified in the contract documents or on the approved working drawings and shall conform to the specified material and manufacturing requirements, Connection hardware shall conform to the contract documents or the approved working drawings. ‘The installation of instrumentation for monitoring corrosion shall conform to the requirements specified. COMMENTARY 161 SPECIFICATIONS 7.643 CONSTRUCTION When required, a precast reinforced or a cast-in-place concrete leveling pad shall be provided at each panel foundation level. Prior to placing the leveling pads, the foundation material shall conform to the requirements of Axticle 7.4.2, “Foundation Treatment.” Precast concrete panels and welded wire fabric facing shall be placed and supported as necessary so that their final position is vertical or battered as shown in the con- tract documents or on the approved working drawings within a tolerance acceptable to the Engincer. Joint filler, bearing pads, and joint covering material shall be installed concurrent with Face panel placement. Backfill material conforming to the requirement in Article 7.3.6, “Structure Backfill Material,” shall be placed and compacted simultaneously with the place- ‘ment of facing and soil reinforcement. Placement and ‘compaction shall be accomplished without distortion or displacement of the facing or soil reinforcement. Sheeps foot or grid-type rollers shall not be used for compacting backfill within the limits of the soil reinforcement. At each level of soil reinforcement, the backfill material shall be roughly leveled to an elevation approximately 30 ‘mm above the level of connection at the facing before placing the soil reinforcement. All soil reinforcement shall be uniformly tensioned to remove any slack in the connection or material 7:7 MEASUREMENT AND PAYMENT Unless otherwise designated in the contract docu- ments, earth-retaining systems shall be measured and paid for by the square meter. The square meter area for ‘payment shall be based on the vertical height and length of each section built, except in the case when alternative carth-retaining systems are permitted in the contract doc- uments. When altemative earth-retaining systems are permitted, the square meter area for payment will be based on the vertical height and length of each section of the system type designated as the basis of payment, whether or not it is actually constructed. The vertical height of each section shall be taken as the difference in clevation on the outer face from the bottom of the lower- most face element for systems without footings, and from the top of footing for systems with footings, 10 the top of the wall, excluding any barrier. ‘The contract price paid per square meter for earth- retaining systems shall include full compensation for fur- nishing all labor, materials, tools, equipment, and inci- dentals, and for doing all the work involved in constructing the earth-retaining systems including, but not limited to, earthwork, piles, footings, and drainage ‘Section 7—Karth Retaining Systems COMMENTARY‘AASHTO LRED Bridge Construction Specifications SPECIFICATIONS systems, complete in place, as specified in the contract documents, in these specifications, and as directed by the Engineer. Fall compensation for revisions to drainage system, or other facilities made necessary by the use of an alterna- tive earth-retaining system, shall be considered as included in the contract price paid per square meter for cearth-retaining system, and no adjustment in compensa- tion will be made therefor. COMMENTARY 1SECTION 8 CONCRETE STRUCTURESTable of Contents SPECIFICATIONS AND COMMENTARY |_Density Conereti 8.2.3 Low-Density Concrete. 83 MATERIALS 83.1 Cements 83.2 Water. 833 Fine Aggregate 83.4 Coarse Aggregate 835 Low-Density Agerogat 83.6 Air-Entraining and Chemical Admixtures.. 83.7 Mineral Admixtures 83.8 Steel. 84.1 Mix Design. 8.4.1.1 RESPO! 84.12 TRIAL BATCH TESTS 84.13 APPROVAL 84.2 Water Content. 843. Cement Content 844 Mineral Admixtures 845 Air-Entraining and Chemical Admixtures 85 MANUFACTURE OF CONCRETE 85.1 Storage of Aggregates. 85.2 Storage of Cement 85.3 Measurement of Materi 854 Batching and Mixing Concrete 85.4.1 BATCHING 8.5.4.2 MIXING. 855 Delivery. 85.6 Sampling and Testing... 85.7 Evaluation of Concrete Strength. 857.1 TESTS. 85.72. FOR CONTROLLING CONSTRUCTION OPERATIONS .. 8.8.5.7.3 FOR ACCEPTANCE OF CONCRETE 8.5.1.4 FOR CONTROL OF MIX DESIGN... 85.75. STEAM AND RADIANT HEAT-CURED CONCRETE 8.6 PROTECTION OF CONCRETE FROM ENVIRONMENTAL ‘CONDITIONS 8.6.1 General... 8.6.2 Rain Protection. 8.6.3 Hot Weather Protection.. 8.64 Cold Weather Protection 8.6.4.1 PROTECTION DURING CURE. 8.6.42 MIXING AND PLACING .. 8.6.43 HEATING OF MIX. 8.6.5 Special Requirements for Bridge Decks. 8.6.6 Concrete Exposed to Saltwater. 8.6.7 Concrete Exposed to Sulfate Soils or Water... 8.7 HANDLING AND PLACING CONCRETE, 87.1 General... eee 8.7.2 Sequence of Placement. ae 3-16 8.7.2.1 VERTICAL MEMBERS... 8.7.2.2 SUPERSTRUCTURES .. 87.23 ARCHES 8.7.2.4 BOX CULVERTS. 8.7.2.5 PRECAST ELEMENTS 8.7.3 Placing Methods 1 GENERAL. 87.32. EQUIPMENT 87.4 Consolidation 8.7.5 Underwater Placement 8.7.5.1 GENERAL... 2 EQUIPMENT... 8.1.53 CLEANUP. 88 CONSTRUCTION JOINTS. 88.1 General 882 Bonding 88.3 Bonding and Doweling to Existing Structures. 88.4 Forms at Construction Joints. 89 EXPANSION AND CONTRACTION JOINTS. 8.91 General 8.92 Materials 892.1 PREMOLDED EXP, POLYSTYRENE BOARD FILLERS CONTRACTION JOINT MATERIAL. POURABLE JOINT SEALANTS. METAL ARMOR. WATERSTOPS '8.92.6.1 Rubber Waterstops 8.92.6.2 Polyvinyl Chloride 8.9.6.3 Copper Waterstops... 8.92.64 Testing of Waterstop Material Biv /89.3 Installation 8.9.3.1 OPEN JOINTS 8.9.32 FILLED JOINTS 8.933 SEALED JOINTS.... 8.9.3.4 WATERSTOPS 8935 EXPANSION JOINT ARMOR ASSEMBLIES . 8.10 FINISHING PLASTIC CONCRETE... 8.10.1 General 8.10.2 Roadway Surface Finish . ane : 8.10.2.1 STRIKING OFF AND FLOATING 827 8.10.2.2 STRAIGHTEDGING 8.1023 TEXTURIN 8.10.2.3.1 Dragged. 8.10.2.3.2 Broomed. 8.10233 Tined aes 8.10.2.4 SURFACE TESTING AND C 8.103 Pedestrian Walkway Surface Finish 8.10.4 Troweled and Brushed Finish. 8.10.5 Surface Under Bearings. 8.11 CURING CONCRETE. 8.11.1 General 8.11.2 Materials... 8.11.2.1 WATER 8.11.2.2 LIQUID MEMBRANES ... ' 8,112.3 WATERPROOF SHEET MATERIALS. 832 8113 Methods. 8.113. FORMS-IN-PLACE METHOD 8.11.3.2 WATER METHOD. 8.1133 LIQUID MEMBRANE CURING COMPOUND METHOD .. 8.11.34 WATERPROOF COVER METHOD... 8113.5 STEAM OR RADIANT HEAT CURING METHOD. 8.11.4 Bridge Decks. 8.12 FINISHING FORMED CONCRETE SURFACES. 8.121 General..... 8.122 Class Ordinary Surface Finish 8.123 Class 2—Rubbed Finish. 8.12.4 Class 3—Tooled Finish... 8.125 Class 4~Sandblasted Finish... 8.12.6 Class S—Wire Brushed or Scrubbed Finish 8.13 PRECAST CONCRETE MEMBERS 8.13.1 General. 8.132, Working Drawing 8.133 Materials and Manufacture... 8.134 Curing. 8.135 Storage and Handling . 8.13.6 Erection .. :PNT Fry 8.13.7 Epoxy Bonding Agents for Precast Segmental Box Girders 8.13.7.1 MATERIALS. : : 8.13.7.1.1 Test 1—Sag Flow of Mixed Epoxy Bonding Agent.. 8.13,7.1.2 Test 2—Gel Time of Mixed Epoxy Bonding Agent.. 8.13.7.1.3 Test 3—Open Time of Bonding Agent 8.13.7.1.4 Test 4—Three-Point Tensile Bending Test 8.13:7.1.5 Test S—Compression Strength of Cured Epoxy Bonding Agent. 8-42 8.13,7.1.6 Test 6—Temperature Detection of Epoxy Bonding Agent 8-43 8.13.7.1.7 Test 7—Compression and Shear Strength of Cured Epoxy Bonding Agent ns 8.13.7.2 MIXING AND INSTALLATION OF EPOXY. 8.14 MORTAR AND GROUT 8.14.1 General 8.14.2 Materials and Mixi 8.143 Placing and Curing 8.15 APPLICATION OF LOADS... o 8-46 8.15.1 General. 8.152 Earth Loads .. 8.153 Construction Loads..... 8.15.4 Traffic Loads. 8.16 SPECIAL REQUIREMENTS FOR SEGMENTAL BRIDGES 8.16.1 Geometry Control : 8.16.1.1 DEFLECTION, MBER DATA, 8.16.1.2 GEOMETRY CONTROL. 8.162 Tolerances..... : 8.16.3 Shop Drawings and Design Calculations for Construction Procedures 8.163.1 GENERAL... 8.163.2 DESIGN CALCULATIONS FOR CONSTRUCTION PROCEDURES .. 8.163.3 SHOP DRAWINGS. 8.16.4 Forms. 8164.1 GENERAL... 8.16.4.2 FORMS FOR PRECAST SEGMENTAL CONSTUCTION. 8.165 Permanent Bearings...... 8.166 Special Provisions for Cast-in-Place Segmental Construction... 8-478 8166.1 GENERAL. 8.16.6.2 FORMING SYSTEM 8.16.6.3 SUPERSTRUCTURE CONSTRUCTION... 8.16.7 Special Provisions for Precast Concrete Segmental Construction .. 8.16.7.1 GENERAL. 8.16.7.2 FABRICATION . 8.16.7.3 SEPARATION OF MATCH-CAST SEGMENTS .. 8.16.7.4 HANDLING AND ERECTION OF SEGMENTS. 8.16.8 Special Provisions for Incremental Launching... 8.16.8.1 GENERAL. 8.16.8.2 CASTING OF SEGMENTS: 8vi8,168.3 GEOMETRIC TOLERANCES... 8.16.8.4 LAUNCHING FORCE. 8.168.5 PIER MONITORING. 8.169 Defects and Breakage...... 8.17 MEASUREMENT AND PAYMENT... 8.17.1 Measurement. 8.17.2 Payment.. REFERENCES. sii soe BATE BAT. 847.14 8-48 B48, 8-48 848.1 8-482 Prony rT}SPECIFICATIONS COMMENTARY SECTION 8—CONCRETE STRUCTURES 81 GENERAL 8.1.1 Description This work shall consist of furnishing, placing, fin- ishing, and curing concrete in bridges, culverts, and ‘miscellaneous structures in accordance with these speci- fications and conforming to the lines, grades, and dimen- sions specified in the contract documents. The work may include elements of structures constructed by castin- place and precast methods using either plain (unrein- forced), reinforced, or prestressed concrete or any combination thereof. 8.1.2 Related Work Other work involved in the construction of concrete structures shall be as specified in the applicable sections of this specification, especially Section 3, “Temporary Works,” Section 9, “Reinforcing Steel,” and Section 10, “Prestressing,” 8.1.3 Construction Methods ‘Whenever the contract documents permit the Contrac- tor to select the method or equipment to be used for any operation, it shall be the Contractor's responsibility t0 ‘employ methods and equipment that will produce sa factory work under the conditions encountered and that will not damage any partially completed portions of the work. Falsework and forms shall conform to the require- ‘ments of Section 3, “Temporary Works.” Generally, all conerete shall be fully supported until the required strength and age has been reached. How- ver, the slip form method may be permitted for the con- struction of pier shafts and railings providing the Contractor's plan ensures that: + the results will be equal in all respect to those obtained by the use of fixed forms, and + adequate arrangements will be provided for curing, finishing, and protecting the concrete. 81AASHTO LRED Bridge Construction Specifications 82 SPECIFICATIONS COMMENTARY 82 CLASSES OF CONCRETE 8.2.1 General ‘The class of concrete to be used in each part of the structure shall be as specified in the contract documents, If not specified, the Engineer shall designate the class of concrete to be used. 82.2 Normal-Density Conerete ight classes of normal-density concrete are provided for in these specifications as listed in Table 8.2.2-1, except that for concrete on or over saltwater or exposed to deicing chemicals, the maximum water/cement ratio shall be 0.45, Coarse aggregate for Class B and Class B(AE) shall be furnished into separate sizes as shown in Table 8.2.21 ‘Table 822-1 Classification of Normal Density Concrete ‘Size of Coarse Specified Min. ‘Aggregate Per Compressive Cement | Max. Water/ | Air Content AASHTO M43 Size Strength Content | Cement Ratio | Range (ASTM D 448) Number | 28 Days) Class of 25 Concrete | kyfm? | kg per kg % Square Openings MPa A 362 049 = 25mm to 475 mm 7 2 ‘AGED 362 045 6415 25mm to.475 mm ST 2 B 307 08 = 50 mm to 25 mm and 3 7 25 mm to 4.75 mm 7 BAB) 307 055 SH15 ‘50 mm to-25 mm and 3 7 25 mm to 4.75 mm 7 c 390 049 = 125mm to 475 mm 7 28 CAB) 390 04s 7415 12.5 mm 475 mm 7 Ey P 334 0.9) ‘As specified 25 mm to 475 mm or 7 As specified elsewhere 19 mm to 4.75 mm 65 elsewhere s 390 058 ~— 25 mm to 475 mm 7 = 8.2.3 Low-Density Conerete Low-density concrete shall conform to the require- ‘ments specified in the contract documents. When the contract documents require the use of natural sand for a portion or all of the fine aggregate, the natural sand shall conform to AASHTO M 6. 8283 SPECIFICATIONS 83 MATERIALS 83.1 Cements Portland cements shall conform to the requirements of AASHTO M 85 (ASTM C 150) and blended hydraulic ‘cements shall conform to the requirements of AASHTO 1M 240 (ASTM C 595M). For Type IP portland-pozzolan ‘cement, the pozzolan constituent shall not exceed 20 per- cent of the mass of the blend and the loss on ignition of the pozzolan shall not exceed 5 percent. Unless otherwise specified in the contract documents, only Type 1, I of If portland cement, Types LA, IIA, or MIA air-entrained portland cement, or Types IP or IS blended hydraulic cements shall be used. Types IA, HA, and IITA cements may be used only in concrete where air entrainment is required, Low-alkali cements conforming to the requirements of AASHTO M 85 (ASTM C 150) for low-alkali cement shall be used when specified in the contract documents cor when ordered by the Engineer as a condition of use for aggregates of limited alkali-silica reactivity, Unless otherwise permitted, the product of only one mill of any one brand and type of cement shall be used for like elements of a structure that are exposed to view, except when cements must be blended for reduction of any excessive air entrainment where air-entraining cement is used. 83.2 Water ‘Water used in mixing and curing of concrete shall be subject to approval and shall be reasonably clean and free of oil, salt, acid, alkali, sugar, vegetable, or other injurious substances. Water shall be tested in accordance with and shall meet the suggested requirements of AASHTO T 26. Water known to be of potable quality ‘may be used without test. Where the source of water relatively shallow, the intake shall be so enclosed as to ‘exclude silt, mud, grass, or other foreign materials. ‘Mixing water for concrete in which steel is embedded shall not contain a chloride ion concentration in excess of 1,000 parts per million or sulphates as SO, in excess of 1,300 parts per million. 83.3 Fine Aggregate Fine aggregate for concrete shall conform to the requirements of AASHTO M 6. 8-3 Section 8—Conerete Structures COMMENTARY‘AASHTO LRED Bridge Construction Specifications SPECIFICATIONS 83 COMMENTARY 8.3.4 Coarse Aggregate Coarse aggregate for concrete shall conform to the requirements of AASHTO M 80, 835 Low-Density Aggregate Low-density aggregate for concrete shall conform to the requirements of AASHTO M 195 (ASTM C 330). 83.6 Air-Entraining and Chemical Admixtures Air-entraining admixtures shall conform to the requirements of AASHTO M 154 (ASTM C 260). Chemical admixtures shall conform to the require- ments of AASHTO M 194 (ASTM C 494), Unless other- wise specified in the contract documents, only Type A, ‘Type B, Type D, Type F, of Type G shall be used. ‘Admixtures containing chloride ion (CL) in excess of 1 percent by mass of the admixture shall not be used ia reinforced concrete. Admixtures in excess of 0.1 percent shall not be used in prestressed concrete. A Certificate of Compliance signed by the Manufac- turer of the admixture shall be furnished to the Engineer for each shipment of admixture used in the work. Said CCntficate shall be based upon laboratory test results from an approved testing facility and shall certify thatthe admixture meets the above specifications. If more than one admixture is used, documentation demonstrating the compatibility of each admixture with all other proposed admixtures, andthe sequence of appli- cation to obtain the desired effects, shall be submitted by the Contractor. Air-entaining and chemical admixtures shall be incorporated into the concrete mix in a water solution. ‘The water so included shall be considered to be a portion of the allowed mixing water. 83.7. Mineral Admixtures Fly ash pozzolans and calcined natural pozzolans for ‘use as mineral admixtures in concrete shall conform to the requirements of AASHTO M 295 (ASTM C 618). Fly ash as produced by plants that utilize the Time- stone injection process or use compounds of sodium, ammonium, or sulphur, such as soda ash, to control stack emissions shall not be used in concrete. ‘A Certificate of Compliance, based on test results and signed by the producer of the mineral admixture certify- ing that the material conforms to the above specifica- tions, shall be furnished for each shipment used in the work. 84 caa6 ‘The types of chemical admixtures areas follows + Type A—Water-educing + Type B—Retarding + Type D—Water-educing and retarding +, Type F—Water-reducing, high range + Type G—Water-reducing, high range and retarding84 ‘SPECIFICATIONS Section 8—Conerete Structures COMMENTARY 83.8 Steel Materials and installation of reinforcing and prestress- ing stee! shall conform to the requirements of Sections 9, “Reinforcing Steel,” and 10, “Prestressing,” respectively. 8&4 PROPORTIONING OF CONCRETE 84.1 Mix Design 8.4.1.1 RESPONSIBILITY AND CRITERIA ‘The Contractor shall design and be responsible for the performance of all concrete mixes used in structures, The mix proportions selected shall produce concrete that is sufficiently workable and finishable for all uses intended and shall conform to the requirements in Table 8.2.2-1 and all other requirements of this Section. For normal-lensity concrete, the absolute volume method, such as described in American Concrete Insti- ‘ute Publication 211.1, shall be used in selecting mix pro- portions. For low-density concrete, the mix proportions shall be selected on the basis of trial mixes, with the cement factor rather than the watericement ratio being determined by the specified strength, using methods such as those described in American Concrete Institute Publi- cation 211.2. ‘The mix design shall be based upon obtaining an average concrete strength sufficiently above the speci- fied strength so that, considering the expected variability Of the concrete and test procedures, no more than one in ten strength tests will be expected to fall below the speci- fied strength. Mix designs shall be modified during the course of the work when necessary to ensure compliance with strength and consistency requirements, 8.4.1.2 TRIAL BATCH TESTS For classes A, A(AE), and P concrete, for low-density concrete, and for other classes of concrete when speci- fied in the contract documents or ordered by the Engi- neer, satisfactory performance of the proposed mix design shall be verified by laboratory tests on trial batches. The results of such tests shall be furnished to the Engineer by the Contractor or the Manufacturer of pre- cast elements at the time the proposed mix design is sub- mitted. For mix design approval, the strengths of ‘minimum of five test cylinders taken from a trial batch shall average at least 5.6 MPa greater than the specified strength, If materials and a mix design identical to those pro- posed for use have been used on other work within the previous year, certified copies of concrete test results 8-5 C8411 Normal-density mix design refers to the American Concrete Institute (ACI), Publication 211.1, 1981. Low- density mix design refers to the ACI Publication 211.2, 1991,AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS from this work that indicate full compliance with these specifications may be substituted for such laboratory tests. Ifthe results of more than 10 such strength tests are available from historical records for the past year, aver- age strength for these tests shall be at least 1.28 standard. deviations above the specified strength, 84.1.3 APPROVAL All mix designs and any modifications thereto shall bbe approved by the Engineer prior to use. Mix design data provided to the Engineer for each class of concrete required shall include the name, source, type, and brand of each of the materials proposed for use and the quantity to be used per cubic meter of concrete. 84.2 Water Content For calculating the water/cement ratio of the mix, the ‘mass of the water shall be that of the total free water in the mix, which includes the mixing water, the water in any admixture solutions, and any water in the aggregates in excess of that needed to reach a saturated-surface-dry condition. ‘The amount of water used shall not exceed the limits listed in Table 8.2.2-1 and shall be further reduced as necessary to produce concrete of the consistencies listed in Table 8.4.2-1 at the time of placement: Table 842-1 Normal-Density Concrete Slump ‘Test Limits ‘Nomiaal Stump | Maximum Stump ‘Type of Work mm im Farmed elements: Seations over 300 25.15 bs ‘nm thick Sections 300 mm 25-100 bs thick or ess ‘Castin place piles 125-200 25 ‘snd dled shafts not vibrated Concrete placed 127-200) ms under water Filing for ripmap 75-175 200 When Type F or G high-range water-reducing admix- tures are used, Table 8.4,2-1 slump limits may be exceeded as permitted by the Engineer. ‘When the consistency of the concrete is found to exceed the nominal slump, the mixture of subsequent batches shall be adjusted to reduce the slump to a value 8-6 COMMENTARY 84BS SPECIFICATIONS Section 8—Conerete Structures COMMENTARY within the nominal range. Batches of concrete with a slump exceeding the maximum specified shall not be used in the work If concrete of adequate workability cannot be obtained by the use of the minimum cement content allowed, the cement and water content shall be increased without exceeding the specified water/cement ratio, oF an approved admixture shall be used. 84.3 Cement Content ‘The minimum cement content shall be as listed in Table 8.2.11 or otherwise specified inthe contract doc- uments. The maximum cement or cement plus mineral admixture content shall not exceed 363 kg/m’ of con- crete, The actual cement content used shall be within these limits and shall be sufficient to produce concrete of the required strength and consistency. 84.4 Mineral Admixtures ‘Mineral admixtures shall be used in the amounts spec- ified in the contract documents. In addition, when either ‘Types I, Il, TV, or V AASHTO M 85 (ASTM C 150) cements are used and mineral admixtures are neither specified in the contract documents nor prohibited, the Contractor will be permitted to replace up to 20 percent of the required portland cement with a mineral admix- ture. The mass of the mineral admixture used shall be equal to or greater than the mass of the portland cement replaced. In calculating the water/cement ratio of the mix, the mass of the cement shall be considered to be the sum of the mass of the portland cement and the mineral admixture, 845 Air-Entraining and Chemical Admixtures Airentraining and chemical admixtures shall be used as specified in the contract documents. Otherwise, such admixtures may be used, at the option and expense of the Contractor when permitted by the Engineer, to increase the workability or alter the time of set of the concrete. 8S MANUFACTURE OF CONCRETE The production of ready-mixed concrete shall con form to the requirements of AASHTO M 157 and the requirements of this Article. The production of concrete with stationary mixers shall conform to the applicable requirements of AASHTO M 157 and the requirements, of this Article. 8.7AASHTO LRFD Bridge Construction Specifications SPECIFICATIONS 85.1 Storage of Aggregates ‘The handling and storage of concrete aggregates shall bee such as to prevent segregation or contamination with foreign materials. The methods used shall provide for adequate drainage so that the moisture content of the aggregates is uniform atthe time of batching. Different sizes of aggregate shall be stored in separate stock piles sufficiently removed from each other to prevent the material at the edges of the piles from becoming intermixed When specified in Table 8.2.2-1 or in the contract documents, the coarse aggregate shall be separated into two or more sizes in order to secure greater uniformity of the concrete mixture 8.5.2 Storage of Cement ‘The Contractor shall provide suitable means for stor- ing and protecting cement against dampness. Cement that for any reason has become partially set or that con- tains lumps of caked cement shall be rejected. Cement held in storage for a period of over three months if bagged or six months if bulk, or cement that for any rea- son the Engineer may suspect is damaged, shall be sub- ject ta retest before being used in the work Copies of cement records shall be furnished to the Engineer, showing, in such detail as the Engineer may reasonably require, the quantity used during the day or run at each part ofthe work. 8.5.3 Measurement of Materials Materials shall be measured by weighing, except as ‘otherwise specified in the contract documents or where ‘ther methods are specifically authorized. The apparatus provided for weighing the aggregates and cement shall be suitably designed and constructed for this purpose. Each size of aggregate and the cement shall be weighed separately. The accuracy of all weighing devices shall be such that successive quantities ean be measured to within 1 percent of the desired amount. Cement in standard packages need not be weighed, but bulk cement shall be weighed. The mixing water shall be measured by volume or by mass. The accuracy of measuring the water shall be within a range of error of not over | percent. All measur- ing devices shall be subject to approval and shall be tested, atthe Contractor's expense, when deemed neces- sary by the Engineer. ‘When volumetric measurements are authorized for projects, the mass proportions shall be converted to equivalent volumetric proportions. In such cases, suitable allowance shall be made for variations in the 88 aS (COMMENTARY. C853 ‘The conventional sack of cement has a volume of one cubic foot and a weight of 94 pounds in the customary US. units. The future SI sack, if that unit is maintained, could differ from previous practice. If so, corresponding changes will be required for mix designs based upon sack units, VY8s SPECIFICATIONS Section 8—Concrete Structures COMMENTARY ‘moisture condition of the aggregates, including the bulk- ing effect in the fine aggregate. ‘When sacked cement is used, the quantities of aggre- ‘gates for each batch shall be exactly sufficient for one or more full sacks of cement and no batch requiring frac- tional sacks of cement will be permitted, 85.4 Batching and Mixing Concrete 8.5.4.1 BATCHING ‘The size of the batch shall not exceed the capacity of the mixer as guaranteed by the Manufacturer or as deter- mined by the Standard Requirements of the Associated General Contractors of America. ‘The measured materials shall be batched and charged into the mixer by means that will prevent loss of any ‘materials due to effects of wind or other causes. 85.42 MIXING ‘The concrete shall be mixed only in the quantity required for immediate use. Mixing shall be sufficient tothoroughly intermingle all mix ingredients into a uniform mixture. Concrete that has developed an initial set shall not be used. Retempering concrete shall not be permitted. For other than transit-mixed concrete, the first batch of concrete materials placed in the mixer shall contain a sufficient excess of cement, sand, and water to coat the inside of the drum without reducing the required mortar content of the mix. ‘When mixer performance tests, as described in AASHTO M 157, are not made, the required mixing time for stationary mixers shall be not less than 90 sec- fonds nor more than 5 minutes. The minimum drum revo- lutions for transit mixers at the mixing speed recommended by the Manufacturer shall be not less than 70 and not less than that recommended by the ‘Manufacturer. ‘The timing device on stationary mixers shall be equipped with a bell or another suitable warning device adjusted to give a clearly audible signal each time the lock is released. In case of failure of the timing device, the Contractor shall be permitted to operate the mixer while the timing device is being repaired, provided he furnishes an approved timepiece equipped with minute and second hands. If the timing device is not placed in ‘good working order within 24 hours, further use of the ‘mixer shall be probibited until repairs are made. For small quantities of concrete needed in emer- gencies or for small noncritical elements of the work, 89AASHTO LRED Bridge Construction Specifications ‘SPECIFICATIONS concrete may be hand-mixed using methods approved by the Engineer. Between uses, any mortar coating inside of mixing equipment that sets or dries shall be cleaned from the mixer before use is resumed, 855 Delivery ‘The organization supplying concrete shall have suffi- cient plant capacity and transporting apparatus to ensure continuous delivery at the rate required. The rate of delivery of concrete during concreting operations shall be such as to provide for the proper handling, placing, and finishing of the concrete. The rate shall be such that the interval between batches shall not exceed 20 minutes and shall be sufficient to prevent joints within a mono. lithic pour caused by placing fresh concrete against con- crete in which initial set has occurred. The methods of delivering and handling the concrete shall be such as wall facilitate placing with the minimum of rehandling and without damage to the structure or the concrete, 85.6 Sampling and Testing Compliance with the requirements indicated in this ‘Section shall be determined in accordance with the fol- lowing standard methods of AASHTO or ASTM: + Sampling Fresh Concrete AASHTO T 141 (ASTM cin) + Weight per Cubic Foot, Yield and Air Content (Gravimetric) of Concrete AASHTO T 121 (ASTM C 138) + Sieve Analysis of Fine and Coarse Aggregate AASHTO T 27 (ASTM C 136) + Slump of Portland Cement Concrete AASHTO T 119 (ASTM C 143) + Air Content of Freshly Mixed Concrete by the Pressure Method AASHTO T 152 (ASTM C 231) + Specific Gravity and Absorption of Fine Aggregate AASHTO T 84 (ASTM C 128) + Specific Gravity and Absorption of Coarse Agere: gate AASHTO T 85 (ASTM C 127) + Unit Weight of Low-Density Concrete ASTM C 567 + Making and Curing Concrete Test Specimens in the Laboratory AASHTO T 126 (ASTM C 192) 8-10 COMMENTARY 8s85 SPECIFICATIONS + Making and Curing Concrete Test Specimens in the Field AASHTO T 23 (ASTM C31) + Compressive Strength of Cylindrical Concrete Specimens AASHTO T 22 (ASTM C 39) 85.7 Evaluation of Concrete Strength 85.7.1 TESTS A strength test shall consist of the average strength of two compressive strength test cylinders fabricated from ‘material taken from a single randomly selected batch of concrete, except that, if any cylinder should show evi- dence of improper sampling, molding, or testing, said cylinder shall be discarded and the strength test shall consist of the strength of the remaining cylinder. 8.5:7.2 FOR CONTROLLING CONSTRUCTION OPERATIONS For determining adequacy of cure and protection, and for determining when loads or stresses can be applied to concrete structures, test cylinders shall be cured at the structure site under conditions that are not more favor- able than the most unfavorable conditions for the por- tions of the structure that they represent as described in AASHTO T 23 (ASTM C 31), Article 9.4. Sufficient test cylinders shall be made and tested at the appropriate ages to determine when operations such as release of false- work, application of prestressing forces, or placing the structure in service can occur. 85.7.3 FOR ACCEPTANCE OF CONCRETE For determining compliance of concrete with a speci- fied 28-day strength, test cylinders shall be cured under controlled conditions as described in AASHTO T 23 (ASTM C 3D, Article 93, and tested at the age of 28 days. Samples for acceptance tests for each class of con- crete shall be taken not less than once a day nor less than ‘once foreach 100 m3 of concrete, or once for each major placement. Any concrete represented by a test that indicates a strength that is less than the specified 28-day compres- sive strength by more than 3.5 MPa will be rejected and shall be removed and replaced with acceptable concrete. Such rejection shall prevail unless ether: + The Contractor, at the Contractor’s expense, ‘obtains and submits evidence of a type acceptable to the Engineer that the strength and quality of the rejected conerete is acceptable. If such evidence Section 8—Concrete Structures COMMENTARYAASHTO LRED Bridge Construction Specifications 86 SPECIFICATIONS COMMENTARY consists of cores taken from the work, the cores Y shall be obtained and tested in accordance with the standard methods of AASHTO T 24 (ASTM C 42), + The Engineer determines that said concrete is located where it will not create an intolerable detri mental effect on the structure and the Contractor agrees to a reduced payment to compensate the Owner for loss of durability and other lost benefits. 85.7.4 FOR CONTROL OF MIX DESIGN ‘Whenever the average of three consecutive tests, which were made to determine acceptability of concrete, falls to less than 1.0 MPa above the specified strength, or any single test falls more than I.5 MPa below the sp fied strength, the Contractor shall, at the Contractor's expense, make corrective changes in the materials, mix proportions, or the concrete manufacturing procedures before placing additional concrete of that class. Such changes shall be approved by the Engineer prior to use. 8.5.5 STEAM AND RADIANT HEAT-CURED CONCRETE, When a precast concrete member is steam or radiant heat-cured, the compressive strength test cylinders made for any of the above purposes shall be cured under condi- tions similar to the member. Such concrete shall be con- sidered to be acceptable whenever a test indicates that the concrete has reached the specified 28-day compres- sive strength provided such strength is reached not more than 28 days after the member is cast. 8.6 PROTECTION OF CONCRETE FROM ENVIRONMENTAL CONDITIONS 8.6.1 General Precautions shall be taken as needed to protect con- crete from damage due to weather or other environmen- tal conditions during placing and curing operations. Concrete that has been frozen or otherwise damaged by ‘weather conditions shall be either repaired to an accept able condition or removed and replaced, ‘The temperature of the concrete mixture immediately before placement shall be between 10°C and 32°C, except as otherwise provided herein.